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"BTW, The center vacuum nipple in the intake manifold has nothing attached, though that made no difference previously. I was told it should have a hose going to the flame trap? Also, my hands ain't tiny, how am I going to get to the flame trap (I believe it's buried under the manifold?)?"
Have you at least plugged that nipple? I can't say that would cure the hesitation, but "false air" (unknown to the airflow meter) getting sucked in is never a good thing.
Flame trap access. I haven't done a B21 in several months, but think I went at it like the pre '89 B230... Remove dist cap and rotor for left hand access (loose interpretation of "access"), and remove(?) —can't recall. IAC hose on B230— whatever on f'wall side of throttle body that will let you snake your right hand around behind.
At best you can then get a couple of each hand's fingers on the FT, and maybe poke at it with a smallish screwdriver as you peer down between intake runners from above. As I recall, that's about as good as it gets.
P.S. I'm also trying to get a 240 "saleable", so I feel your pain. Mine is a decent-running, rustier than it looks a first glance, '85 244ti that leaks AT fluid and glows a solid BFS light on Low Beams. That's where I am now. It was worse.
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Bruce Young
'93 940-NA (current), 240s (one V8), 140s, 122s, since '63.
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