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You are correct ! On the older dt466, the check valve you are referring to also acted as a pressure regulator for the fuel system and maintained pressure in the system .
On the newer dt466, this fuel pressure regulator is now built into the fuel filter housing. If you remove the filter cap , and pull the filter out , you will see at the bottom of the housing , next to the standpipe , there will be your fuel pressure regulator . You will need an allen socket or wrench to remove it and replace it with a new one..I would start there , cause it is an inexpensive fix and see how it goes !
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Any luck yet ! Just wondering what your fuel pressure is sitting at when running and if there is any air in it?
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We usually pressurize the fuel tanks with about 5-10 psi of air pressure to check for leaks in the lines on the suction side. Normally you would not see leaks on the suction side because air is drawn in but when you pressurize the lines and wait about 5 minutes, if lines are bad , you will eventually find something starting to dribble. Might be a quick coupler leaking from the O-rings or something but better to pressure test while all is connected .
This however does not test the standpipe inside the tank. To test this , you would have to hook up a line from another fuel source to the filter housing to see if by using another fuel source, the air bubbles go away. This would tell you if your problem is in the standpipe. I have not seen this very often but it is possible to be a standpipe problem if nothing is found on the outside.
If after this test is done , and you still find air in fuel , then you may be looking at replacing your fuel filter housing. This I have seen a little more often.
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Now , it looks like some of the compression gaskets for the fuel injectors might be leaking compression into the fuel system . I would pull the valve cover , then the high pressure oil rail manifold to expose the injectors . pull all the injectors out and inspect. The washers on the very tip of the injectors is your compression gasket . Make sure they all came out with the injectors . If injector tips look fine, I would replace all injector o-rings and compression gaskets . Re-install and torque to spec. ALso have to replace all oil rail seals before re-installing manifold back on injectors . Torque to spec. That should cure your problem . Air can't be coming from anywhere else !
No problem and yes I have seen loose injectors! They have to be properly torqued or they could come loose!
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No problem ! It's 30 ft/lbs
oil rail manifold bolts are 23 ftr/lbs. And you should torque the manifold starting with the center bolts and work your way toward the ends.