I don't know whether to
or
. It's great to hear that your careful, patient and systematic diagnostic work has resulted in success.
I can't remember whether you've had a KV6 before but regarding the manifold chamber rattle, remove the VIS power actuator and check that the valves operating rod is attached properly to it. The VIS balance actuator flap is notorious for sticking in the half way position (ease it with some fine abrasive paper).
Looking forward to the next instalment.
Simon