Colt, I saw your icon was green when I loaded the page but by the time I logged in you had already "left". I will help out as much as possible but I am not a mechanic, just mechanicaly inclined as you seem to be. This is def a do it yourself job if you are organized. Again you seem to be. Here are the things I can help you with your list.
2. There is only one EGR gasket. 7-8 bucks
3. Make sure you use a
very high gain emory cloth. I didn't use any. I used a razor and cleaner to make sure all mounting surfaces were clean. The T/B cleaner should be good enough. Remember, the parts you are cleaning are aluminum so you dont want to cause any scratches. The gasket wont seal properly and you will develop a vaccum leak.
7. I put Iridium in mine. 41-101 AC Delco for around 7 a piece.
12. 10mm for intake bolts from what I remember.
15. I loosened the rockers just enough to take the pushrods out by hand. No special tool used.
18. Fuel rails... there is a shrader valve on back fuel rail by alt. Put a rag over it and depress to relieve fuel pressure. 9/16 SAE on back rail and No. 27 torx for front rail. Make sure to remove the fuel sensor retaining clip from the fuel rail and keep it with the torx bolt. I had a hell of a time finding mine as I left it on the rail. Well I didnt take the rails off the lower intake and when I was cleaning it, the clip fell off. Took over two hours and a trip to the parts store to find out its a GM specific part.
As far as the plastic connectors go, there are a few different kinds. I used my fingers and a flat screwdriver for most. Just make sure that you put the clips that hold the ends together back in the harness as to not lose them.
If you have access to a digital camera, I highly advise taking pictures of the tear down so you can reference them on the rebuild if you need to. If I or others are not around, check this site as its VERY VALUABLE to someone tackling this job. They put all the technical stuff into words the average joe can understand.
BNaylors link from my original post.