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Can you see the IAC #s fluctuating while you're starting it, or does it stay static (slaved to the ECT)?
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I don't know. I think the thing to do next is log the IAC numbers and watch what the ECM does to get the motor to the target idle speed. That might be a clue to see what is going on.
About the leaning problem, something just occurred to me: I wonder if the issue was that we didn't change the fuel calc parameter for Injector Flow Rate. At 60 psi, the injectors flow more fuel right? So the number should have been more increased quite a bit ... maybe to 55 psi or something. Perhaps the ECM got confused, and was calculating the fuel load based on the smaller number? I can't quite wrap my mind around that (it's 2 am here on the East Coast, lol).
But I know we didn't change that value.
jp