I had to replace my VP-44 a few years back (haven't most of us) and lost one of the steel reinforced o-rings for the return line banjo bolt. I went to the Dodge dealer and obtained a new replacement but found the I.D. to be very tight. I installed it with some damage to the rubber but it seemed to work; the truck started with less than one crank and ran fine.
Lately it takes 10 or more revolutions to get it started. I've traced all fuel related lines, checked all connections and injectors, no signs of leakage. I've determined the cause to be the damaged o-ring on the fuel return line allowing loss of prime.
Friend of mine with same engine uses copper o-rings in that application and has no issues with leakage or pressure loss.
Does anyone have any experience with this copper o-ring usage? Or, does anyone know where I can obtain the correct size steel reinforced, rubber o-rings on the web?
Thanks.

 

I've used these guys many times......

http://hoeslidiesel.com/store/page3.html

There are two different sizes IIRC, so give 'em a call to make sure you get the correct ones.

 

wouldn't any cummins dealer carry the washers, I think they were only a dollar or two

 

Yesterday I ruled out the fuel system as a source for the long crank times when starting the engine. No leaks anywhere and the copper washers sealed just fine on the return line. However, thanks for the information.
Now I'm looking at possible failure of the crankshaft position sensor and or the camshaft position sensor as possible causes for the long starting times. I have the Dodge shop manual for the truck and while it tells me that the ECM and PCM take input from both of those sensors during the starting sequence, it fails to mention where they are located on the engine. Or at least I can't seem to find it.
Does anyone out there know?
Thanks.

 

If the engine starts normally when parked downhill, it probablly means there a is a air leak into the return system.
To my knowledge the crankshaft senson was deleted on 2000 models.
Camshaft sensor is located between the VP44 and block. Difficult to get to, but possible.

 

heres some reading for general VP diagnoise.
http://www.bluechipdiesel.com/vp44diagnostichelp.html

I'll agree a pin hole in the return WILL cause the fuel to syphon back to the tank causing hard starts, you can also try leaving the fuel cap loose, this eliminates the tank vacuum pulling fuel back to the tank, so it could also be a faulty fuel cap and or faulty tank vent.
If you have a sensor failed 99.999% of the time its going to trip a code, (but not always the check engine light).
also another point of air leaks is at the connector tubes, each of them have an O-ring and they do fail, usually you may see a little seepage/fuel stain,

 

On the '99 Model Year, the crank position sensor is located in the drivers side of the block, near the starter. In 2000, there is no crank position sensor. In '01/'02, I am fairly certain the crank position sensor is located at the front of the engine. There should be a tone ring on the back of the balancer/pulley.
The cam position sensor is mounted in the same spot on all 24v. Just below the vp44, mounted in the back side of the gear housing.

A new cam position sensor recently cured similar hard start issues with mine, but I did have a check engine light and code

 

There is no tone ring on the back of the Harmonic Dampener, nor is there a Crank Position Sensor through the timing cover on the front of the engine. There isn't on my 01 anyways...

The ECM reads RPM off of the Cam Position Sensor (for your 02) located underneath the VP44.