Ok - I figured I'd come back and post what the problem turned out to be.
Whenever I messed with the wires near the pump I would jostle the pump enough and it would start, but I didn't realize that's what I was doing
After a few of these events I thought it may be the fuel pump intermittently working so I figured I'd try tapping the pump the next time it wouldn't start. Sure enough that did it - just a quick tap got it running again - so main fuel pump failed.... Replaced it with a good pump I had from my old 240 and went to start it up again and nothing - after several cranks it finally started - then I remembered that BB'ers said main pumps fail after the in tank pumps failed and caused the main pumps to overwork delivering fuel. So I listened for my in tank pump and heard nothing.
After more disassembly and stethoscoping the intank pump it was clear that I had found the culprit of the whole problem - an unnoticed failed in-tank pump. Ordered the part from FCP and now am hearing the hum of two fuel pumps.
If only I had heard the in-tank pump fail!
How would anyone notice their in-tank pump was no longer working without regularly checking it?
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Bad Blue - '86 245 with 303,000 mi. (now for parts), Good Green 1990 245 with 178,000 mi., Blacky - '91 740 wagon with 180,000 mi., Mean Green - '94 850 with 222,000
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