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Air is typically the culprit, but it seems - more times than not - to be getting in as a result of not hitting the stops on the DFCM filter. Even when tight, people have had issues before with air getting in if the stops weren't fully met. You mentioned you checked the o-ring on the drain valve. Did you lube the housing o-ring before installing and verify no defects and proper seating? Mine only made noise during the priming process and for about 30 seconds after my first start, but has been silent since. Hope you find a fix quickly and easily!
My truck makes a sound like the LPFP is dying every time I start it. We hooked the IDS to it, started playing with everything, manually turn the LPFP on and off. The noise would go off. When he(SMT) called the hotline, the techs told him that the pump is purging "air" out of the system.