In post #100 you say the instructions said to "rotate until intake opens then set exhaust". You sure it didn't say to "rotate until intake opens then continue rotating until intake is almost closed then set accompanying exhaust preload"? That's what instructions for all I've ever done said. Not continuing to rotate until intake is almost closed exhaust may have not been quite on base circle and be the source of your light clacking (not quite enough preload). I don't know, just a thought.
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