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Ok I see what you did. What year is your 240? I'm sure removing egr entails the same thing for all years 91-98 but my experience is only with 91-95 OBD1 motors. I sincerely believe your problem to be a vacuum leak so the focus of my response will be on potential air leaks.
First and foremost, where is the FPR getting its vacuum? It should be getting its source directly from the nipple coming off of the intake manifold, next to where the brake booster receives its vacuum.
You mentioned that you reapplied rtv on the block off plate which is good. I had a vacuum leak from there once, albeit a small one, and it caused rough idle and stalling. Just make sure it's 100% sealed is all.
I feel like your problem is somewhere here: Look under the throttle body. There are several small vacuum nipples coming out (number will depend on your year). The thickest one (this one runs from the purge canister) should be capped as it will be an open leak. The one that comes DIRECTLY from the throttle body should be capped as well. The rest, if you did everything correctly, won't need to be capped since they are no longer exposed to vacuum. Simply remove the lines (one will lead to the AIV, another to the PAIR, another to the charcoal canister, and the think one I mentioned earlier to the charcoal canister). On the back of the block, those relays and the bracket can be removed (3 12mm bolts holding it up). The vacuum lines can all be pulled as they now no longer go anywhere....This is very difficult to explain without diagrams so I hope this is not too confusing.
An easy way to test if you have any vacuum leaks (free and easy) is to put your mouth on the hose that runs to the IACV and blow, creating pressure... kind of like a little boost leak test. This will help show where air is escaping. Try all this and report back. Everyone else let me know if I missed anything or if I said something incorrectly. Best.
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