OK the first thing that I see is the original coolant temperature sensor, they were very unreliable. You need to update it with
GM Closed Element CLT / IAT Sensor with Pigtail
It comes with a new connector also, the old ones caused a couple of problems.
Second please tell me that those are not ignition wires zip tied to your wire harness!
Now, when spraying your wd40/carb cleaner around to find vacuum leaks it is sealing the leak so unmetered air isn't going into your intake hence it smooths out the idle. Spraying into your carb means nothing (at this point in the repair). As said before you need to isolate all the external devices that are controlled by a vacuum hose which in your case is the headlight doors, canister purge and thermac (air cleaner) if used. You Do need to have the correct PCV VALVE, a CV774C AC DELCO, not what ever the parts store wants to sell you. It is a calibrated vacuum leak and the wrong one will either allow to much air through making it difficult to correct with your MC solenoid or not enough and then it allows to much pressure to build up in your crankcase which unturn causes oil leaks.
I do not understand why Peer81 would use the EGR port for a vacuum check, it is ported (only has vacuum when the primaries are open, not at idle) you want to check Manifold vacuum at idle at the Manifold!
As for base ignition timing that was a good find with your TDC mark!
You didn't say if you by passed your EST (Electronic Spark Timing) when setting it
Check your ignition module, AGAIN if it's an aftermarket one it WILL NOT have the proper spark advance built into it. Less power or spark knock will occur.
Check your PROM (Programable Read Only Memory) some are better than others, you don't want one with California emissions!
And PLEASE post before or during your carb re-calibration, there is a lot more to it than what is printed on the rebuild kits instructions.
Provided that there isn't any mechanical problems with your engine I know we will have you up and running soon
Hang in there,
Doug
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