Everything i have done/ replaced new aluminum plenum pan, plenum pan gasket, intake manifold gasket, coolant sender switch, fuel injector upper and lower o-rings replaced, throttle body gasket, oil and filter change, and coolant flush

 

I did clean the throttle body while i had it off took all the sensors off and cleaned it thoroughly with brake cleaner than let it dry and reinstalled the tps ect. Where should i start new plugs?

 

I've run Platinum plugs in all my mopars without any problems so ignore that for now...

First make certain you have everything hooked up correctly...connectors, vacuum lines, hoses etc. Then check for vacuum leaks with it running.

Do you have the firing order correct? Did you remove the distributor?

Also, disconnect the battery for a few minutes then reconnect it and restart it then drive it a bit and see how it does and then check for codes.

As CW pointed out you should probably go ahead and replace your O2 sensor due to the oil you have been burning...once they get all "carboned" up they do not work very well.

 

you could try gapping the old plugs and re-installing them if you still have them. most people just run copper core plugs of some sort and they work the best in these trucks. i personally like the ngk v-groove ones.

 

I made sure everything was put back on right. I went out and started it up rough idle and when i gave it gas it started to stall so im guessing vacuum leak? One upside is the notorious plume of doom is gone

 

So where should i start buying a new IAC or what else could it be?

 

No...as said before start with checking it over good for vacuum leaks, firing order, etc and your 02 sensor

An idle speed controller is not going to make it idle rough

 

Do a vacumn leak check with carb cleaner

 

you could try removing the o2 sensor and see if it runs better. if it does run better then it means your cat is clogged.

as far as vacuum leaks go you could try hooking up a vacuum gauge somewhere and see what it says.

 

Simply removing the 02 sensor and running the vehicle is not going to tell him if the cat is plugged unless he installs a back pressure gauge to see how restricted the converter is. That small opening isn't enough to relieve the back-pressure even if it was plugged to determine if the cat is plugged.

As far as the vacuum leak how is hooking a vacuum gauge going to tell him anything? A small leak that is enough to cause a rough idle or stalling on a FI vehicle would never lower the overall vacuum enough to show on a vac. gauge. A leak big enough to show on the gauge he would clearly hear and the engine would barely run.