How long do you leave the insulin at room temperature? It can take the day or two you mentioned for air which is dissolved in the insulin to come out of solution and show up as bubbles. On the rare occasions when I can get myself to think ahead, I will fill the reservoir and let it sit at room temperature for a day or preferably two before using it. This gives any air in solution a chance to emerge.
It might also help to attempt to equalize the air pressure in both your insulin vial and any pre-filled reservoir. I add an extra step to try to accomplish this.
First, I remove the reservoir as Medtronic suggests by holding the vial upright with the Medtronic reservoir connector still attached to it. This allows any excess air pressure in the vial to escape/equalize. The pic below from the
Medtronic "Filling Your Reservoir" instructions illustrates this.
After doing this I rotate the reservoir 180 degrees so that the reservoir connector end is now "up" and the plunger end is "down". I then reattach the blue "Transfer Guard" connector to the reservoir to let the air pressure in the reservoir equalize. Doing this briefly is probably enough. But since I don't expect any "contamination" is going to get into the insulin via the needle in the blue "Transfer Guard" I have also just left it on while waiting the day or two before using the reservoir.
I don't know how much the above helps, but it's the approach I take to filling a reservoir.
For some reason I can't figure out what you are suggesting here. There is always a gap between the pump piston/plunger when I put in a new reservoir since I've rewound the pump. And of course, that gap has to be closed for the pump to work. I'm just not understanding the suggestion.