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This is one of those scenarios where a scanner is dang handy, no matter what some people will tell you. Counting the flashes on the dashboard, using a DMM, and rattling some chicken bones over the car just isn't enough sometimes.
Something to consider: You state the car starts o.k. when hot - if injector(s) were leaking the car would probably be difficult to start hot as well.
Need more info: When the car finally starts cold does it immediately idle o.k., without your foot on the gas? Or does it stumble a little at first? When you turn the a/c on does the engine hold the same idle speed or does it drop and stay down?
Hopefully you can put the TPS back in its proper position. While the car can still run with it out of range, that's not exactly how you want your car set up, is it?
If I've got this right, you just had your engine rebuilt? If the mechanic that did that can't correct the problem you need to find someone that can. Just throwing parts and guesses (shotgun approach) can get awfully expensive and sometimes make things worse. We get a number of new sensors, etc. that are DOA and can confuse the situation.
My suggestion would be to take the car in and get an estimate. When they tell you how much it will cost make sure everyone agrees that $xx.xx will fix *this* problem. If they can't assure you of that then you need to find another garage.
Beav
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