How to test and adjust the TPS:
http://www.4crawler.com/4x4/CheapTricks/TPS/index.shtml#TPSAdjustment

Bascially you are setting the IDL-E2 resistance to be less than 2300 ohms when the throttle is closed and then more than 2300 ohms (or infinite) with the throttle open a little bit.

Thanks, I was just looking at that page and came back to update about it <img src="/forums/images/graemlins/smile.gif" alt="" />

To those who have actually calibrated/set their TPS...

The procedure states to 'slowly turn the TPS until the values change'. I'm finding that I can barely turn it an amount small enough between open and when the readings change. I mean, its rediculous and near impossible to move it such a small amount. Is that what others have found as well? Or should there be a greater range of motion between the edge of an open reading and when you start seeing ohm values change?

It is an on/off sort of setting. As I note on my web page, the actual values of throttle opening likely make little different, I mean if you can adjust it to +/-0.01mm go for it. But for the rest of us, I just go for less than 2300ohms when the throttle is closed and when it opens a little bit (0.85mm per the FSM), the reading goes infinite. But whether that "little bit" is 0.80mm or 0.90mm or even 1.00mm probably makes little difference at all. And the value of resistance you measure for "less than 2300 ohms" really doesn't matter either, 100ohms < 500ohms < 1000ohms < 2299ohms < 2300ohms. If it is less than 2300 (or 2.3K) ohms, it is good.

Picked up some hex head screws to replace the phillips head screws on the tps today and also shot the backside (spring) with cleaner which greatly improved its response. It looks like I got it dialed in now as I got the drop in idle when jumping the diagnostic pins and the timing was only a couple degrees off. I also pulled the timing cover and adjusted the valves again (first time since assembly and getting it running). It sounds a lot better now

However... it still seems to not be firing on cylinder 1. I get absolutely no change when I pull the wire off the plug, even though there is spark through the wire.

I've also had a hell of a time with the ends coming off the wires and staying on the plugs when I pull them. I'm not pulling by the wire, always by the boot, and even using plug wire pliers it is still happening. Is this common? Maybe I need to lube the tops of the plugs...? Luckily I'm getting them replaced under warranty, but its getting old having to go get them replaced <img src="/forums/images/graemlins/angry.gif" alt="" />

As for cylinder 1, I'm wondering if it isn't a fuel issue now. The plug is always a bit wet when I pull it, but maybe I have a problem with the injector or something. I'm running out of things to check!

What plugs and wires are you using? I only use Toyota wires and NipponDenso plugs from Toyota.
I have used others and having to chase issues like you are, well, it isn't worth it

dOn't know if someone has suggested this but do a comp test to see if comp is low in #1. If so look into a valve sticking open.

Currently using NAPA wires, getting them replaced under the warranty but they're actually pretty beefy. The other ones were crap from Advance Auto that I was just using to try to rule out that the problem was with the wires.

Plugs are NGK's which I've always had work good for me.

I did a compressioin check earlier on and it was good.

Well after all the troubleshooting and fine tuning, I finally figured out my cylinder #1 problem!!! The injector plug was loose <img src="/forums/images/graemlins/shiner.gif" alt="" /> I thought I was getting fuel but the plug must have just looked wet from cylinder oil or whatever. What a noob <img src="/forums/images/graemlins/baby.gif" alt="" /> <img src="/forums/images/graemlins/rolleyes.gif" alt="" />

I just wanted thank everyone again for the helpful suggestions, and especially for kewlynx's and 4crawler's help in getting the TPS dialed in getting the timing set. The whole rebuild has been a great learning experience and I don't regret doing it myself at all. <img src="/forums/images/graemlins/cheers.gif" alt="" />