Yep, sure enough, got that intake off and it was definitely a dead port. Thanks all.

Now I'm going to find that good plenum repair kit so I can solve that problem before I get the new motor in. Hopefully I can find some gaskets that don't disintegrate either - when I got the intake off, it was clear there needs to be a better gasket material. Battles for different days.

 

I would be tempted to get a manifold from a slightly newer engine (96 or 97) that DOESN'T have the EGR provisions... and then removed the center divider wall.... Maybe even cut down the runners a bit..... Open it up some and let the engine breath better.

 

I got the Hughs Engineering plenum kit. I heard about it here. The stock plenum seal would be okay, but the thicker kit is impressive. My engine had been worked on before, hence the cigarettes and beer can inside, but the beer can explained why mine failed. Some of the bolts were so tight I had to put the intake in a vise and use a cheater pipe to get the bolts loose. Other bolts were finger tight. I try to stay in shape but I shouldn't be able to turn small bolt heads with my fingers. Not even grabbing hard.

I did put a thin film of RTV on the gasket even though I don't think it's called for. It sure beats the shellac used years ago.