You folks have been great in responding to my questions so I wanted to let you know the outcome. I measured the coolant and manifold temp sensors with ohm meter and they were within spec. Measured MAP sensor voltage...it too was in spec. Didn't measure knock sensor and am not sure how to measure AC request signal.
I just happened to have a 4.0L engine in my shed (had picked it up from boneyard two years ago with thoughts of doing a rebuild at my leisure and then swapping next time clutch needed changing) Anyway I took the TPS and IAC from the spare and installed them on the car. I had removed the battery cable two days ago just in case there was ECU memory that might need to be erased. I installed the parts, attached the battery cable, adjusted the TPS for 0.8 volts and fire it up. Much to my dismay the idle was still real high. I turned off the car and checked to see if I left something disconnected. Restarted the car and idle fell to normal like nothing was wrong??? Now I really was confused and worried that I had not fixed the problem and that it would show up again.
Since I had changed two parts (IAC and TPS) I wondered if putting the old IAC motor back on would show anything. I swapped them but still worked fine. I knew the original TPS was flaky so I left it but bottom line is that I'm not sure what the fix was.
I wonder if the original TPS had confused the ECU and the IAC position was trying to adjust the IAC to match what the TPS was wrongly indicating. The new TPS fixed that but since the IAC (during the swap) was moved from its "home" position the ECU didn't know where it was. The first start had the IAC position in this unknown position so the ECU didn't know what to do. When the car was shut off the IAC was set to "zero" so the next time it was started the ECU knew how many pulses to give the IAC to put it in the right position?? Just a wild guess and not from anything in the manual so I could be way off base.
Any thoughts? Thanks again for pointing me in the right direction. I still have the spare motor complete with manifolds, alternator, harness, etc. so if anybody needs it let me know. I have 240000 on my motor but oil pressure is still 60-lbs at cruise so I don't plan on rebuild. Got a leaking real seal that I'll fix when clutch needs changed but other than that motor now runs like a champ.
Dan