I removed the throttlebody and everything today in preparation of installing this new head that I picked up from Rob. As soon as I took it off I noticed that the intake manifold is absolutely caked in grime. Ive got a breather filter on the valve cover so nothing should be circulated back into the intake tube so I wasnt expecting it to be this nasty. Is this normal? I'm assuming not and perhaps this is the cause of my stuck valve. I took some pics, but they didnt turn out very well and I'm not sure how to post them here. TIA! Mark.

thats from the EGR valve. the breather filter on the valve cover stops oil from going back into the intake. A EGR blockoff plate will solve that problem its towards the bottom of the intake mani.

I can clean it out and make it shiney for ya Mark

but with an EGR blockoff it will make the ECU throw a CE light will it not?
and yes that grime in the intake manifold is typical, every intake I've ever taken off a motor has to be put in either the jet washer or the cold parts cleaner at the shop to get that stuff off.

yeah, i've been wonder what would happen when you block off your egr valve. i know you loose a little gas mileage. is that all? will the CE light come on?

Blocking of the EGR valve only causes a CEL in the California cars. I doubt you'll notice any difference in gas mileage. If you've got a California car which I highly doubt, you can still block it off, just keep the EGR sensor plugged in.