A stepper motor fault could cause the high idle, but I can't see how it could cause a high idle (suggesting pushing on the throttle linkage too much) and also a tendency to die when in gear (suggesting not pushing on the linkage enough) - the two are contradictory.
Forgot to mention above when discussing sources of vac leaks, of course the inlet manifold gasket itself is another possible source of a leak. Some questions for you:
- Was the inlet manifold gasket renewed, and is it all up tight?
- Have you reconnected all the breather pipes to the inlet manifold?
- Have you reconnected the servo vacuum hose at both ends and is it in good condition?
- If you pump the brake pedal until it is hard then start the car, does the pedal go down as the servo applies vacuum?
- When you run the engine then switch off, can you hear the stepper motor cycling?
- Have you tried feeling at the back of the manifold where the vac pipes attach to see if there is a vac leak where the pipes attach?
- What happens to the idle speed if you disconnect the red pipe from the underside of the air box?
- What happens to the idle speed if you disconnect the vac pipe at the ECU end?
- Is the throttle potentiometer plugged in correctly? Also was this removed from the manifold at any point?
Cheers
Craig