I did connect directly to the line getting 30 psi. I actually never did connect a T in the line because at the time I did the test I was unable to find the correct fitting. The new fuel pump arrived and is going in today.

Steve,

If the system is working correctly, what sort of flow should I be seeing downstream of the FPR on my 300e?

I have just put on a new fuel pump, the distributor is a fairly new secondhand unit and the FPR is only a month or two old. Flow on the in and out sides of the distributor is a litre in 30s as per the book but the flow out of the FPR is much lower. Is this correct?

I'm still battling residual contamination from water in my fuel system due to a leaking carbon filter but that seems to be fixed now. I'm hoping I don't have to replace any more parts.

cheers

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1987 300e manual 250,000 km (sold)

If you have any flow from the FPR return I would expect you're ok. Verify the distributor inlet pressure to be certain, though.

Steve

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'91 MB 190E 2.3
'08 RAV4 Ltd 3.5
'83 Lazy Daze m'home 5.7

Billro, Im getting the feeling that the fuel pressure gauge you're using might be "out of whack" Just as mentioned before, if you are getting a return flow, from the FPR, you might indeed have enough pressure. Remember, you are looking for 80PSI BETWEEN the fuel delivery line and the fuel distributor body. During all these no start events, have you been checking for spark? Although spark might be present at all times, it could be WEAK, and breaking down under compression. Are the plugs wet and gassy smelling right after a no start episode? A new ignition coil could be the answer....
A good spark is whitish blue, not brownish orangy red..... Do yourself a favor, and try a another coil.
Dave......