Got my hands on a spare Throttle body which I want to play around with, try to bore it out etc, as I have nothing to loose with it. I am pulling it totally apart and have the factory manual on hand, but in reference to the Fixed SAS screw, their is another small screw to the right of it, near where the throttle cable attaches. This screw has an Allen key recess on it and it contacts the throttle lever.

I cannot find any reference to this screw or how to adjust it. It's sole purpose seems to adjust the gap between the the 2 throttle blades where feeler gauges are placed to adjust the TPS.

As per the manual once the SAS is adjusted by turning it another 1 1/4 turns after it contacts the throttle, the gap between these 2 blades widens to a point too wide for feeler gauges of 1.4mm, therefore not allowing proper adjustment of the TPS. Obviously if this gap is too small inserting feeler gauges of the above thickness will also cause incorrect adjustment of the TPS.

Using my original TB which I'm not touching, there seems to be a gap of about .60mm between these 2 blades.

Anyone got any suggestions on the proper adjustment of this screw?

That allen headed screw is there for a good reason. Back it off and move the throttle lever, you will find the throttle blade binds on the throttle bore. Wind the screw back in just enough for the binding to stop. It's set at the factory like that and should not need to be touched, unless you . . . . .

The feeler gauge is used to get a "just open" on the throttle, where the TPS should switch from idle to running, ie the contacts should open.

The SAS screw can only be adjusted on a running engine.

(I expect Mal to chime in here and set me straight on my errors. lol )

READ: http://autorepair.about.com/library/a/1g/bl620g.htm

This allen key headed screw I am referring to adjusts the gap between the free lever which the accelerator cable attaches too and the throttle lever which the SAS screw adjusts. I have the procedure for adjusting the SAS Screw and TPS, but cannot find any reference to this allen key headed adjustment screw for the free lever in the workshop manual.

The posted link was an interesting read.