For your "weird hesitation/throttle problem. It feels like its not getting enough fuel" Try a Brute Power P/N 2910260MS fuel pump. It's a direct replacement for the stock pump. If you have an adjustable reg. Set it at 39 psi. Big time improvement over the stock [probably 30yr old] Toyota p...

Pass on the form in place RTV gasket type sealers. The typical 30 yr old oil pan mounting flange is not very straight even after trying to remove all the dimples from over tightening the pan bolts. Use Fel-Pro pan gasket set 2-92981. Has two gaskets, one for the pan and a 2nd for the wind tray. Clea...

An exhaust option is the 20V exhaust header. You would have to cut them just be low the 2 into 4 merge point, and do a 90* turn out the engine bay. You may also have to route the steering shaft around the exhaust. I would go with Jondee86 suggestion, even with a stock big port and up the compression...

You did not mention your idle speed? Try increasing the idle speed by adjusting the air bleed screw that is located under the black plug on the throttle body. Davew7

I deleted my booster, but used the stock M/C, by changing the pedal leverage. For a manual system you will need a pedal leverage in the 5 thru 7 to 1 range. It just requires you to move up the pivot point where the M/C push rod attaches to the foot pedal arm. You should also raise the M/C on the fir...

There should be a high amperage fuseable link in the circuit. Check the connections and verify that the link is good. On the USA models the fuseable link is located near the battery. davew7

With the fan belt off, if you turn the water pump by hand do you feel any resistance or play in the shaft? It does sound like the water pump. I would say you got your monies worth if it the original pump. Really not that bad of a job to replace. Just do not over tighten the belt when installing. Dav...

I would bet that the Hitachi Automotive Systems corporate office already has hundreds of benchmarking studies on file, for all major shock suppliers. See if they are willing to share the info. That would narrow the field for any additional testing. davew7

I believe that it is more tire and air temp related, then tire compound. Even with road tires on hot summer days they get sticky enough to through up a lot of stones. Davew7

You are not going to gain much depending on the current diff ratio. My guess is that you will have to change to a lower diff ratio. You will probably need a 4.3 gear set, and I would also try to work in a lite Wt flywheel into your build plan. davew7

notnilc20 " next project for the 86. I just have a bung at the top of the tank and have it vent to atmosphere?" As I mentioned, there is already a vent tube on the fuel pump mounting bracket. No bung needed. Just add a hose to the current vent tubing that makes an up-ward loop. Make the lo...

I do not think that type of vent inside the filler neck would pass emissions in the USA even back in the late 80's. Some states [Calif] even required the gas pump nozzle to seal against the filler neck while filling the gas tank to prevent vapors from escaping. That type of system required capturing...

The USA gas tank for an AE86 had to 2 vent tubes right above the main filler hose connection. There was also a vent tube on the fuel pump mount, along with the output and return tubes.
Davew7

Thanx for sharing your project. Looks like a fun build. davew7

I think jondee86's idea that you have a fuel pump problems is the most likely. When the motor stops, try spraying quick start in the plastic vacuum connector on the manifold. If it runs for a second with the quick start, then you know it is a fuel issue. These fuel pumps have a limited life. davew7

The GTS 4AGE never came with a start under the intake. You my want to look at a 4A-C engine.
Davew7

If you end up removing the valve for testing, then try cleaning the valve with carb/choke cleaner. Some times the valve gets gummed up, and the carb cleaner will free up the valve. As Jondee86 mentioned, verify you have water flow "to" and "from" the valve. If all else fails, you...

Take totta crolla's idea one more step. Make the throttle pedal arm adjustable. I used the cable eye end from the stock pedal, and threaded it into a lower tube section. You can then thread the arm length up or down, to the vary the leverage i.e. travel. Once you get the correct length lock it down ...

Thanx jondee86 The oil requirement chart is very enlightening relative to the amounts needed. I did not realize that the main bearing needed that high of a percentage when compared to the rod ends. The one thing you did not mention is the actual cooling of the bearings. Thinner viscosity oils will h...

There is a high probability that they have the right spline count in stock. They had a Toyota to English rack U-joint in stock that I needed. I got my U-joint from Sweet but both suppliers have excellent quality. Davew7

Try Flaming River or Sweet Mfg. Half the cost of Toyota and it will not rust. You just need Dia. and spline count. Davew7

Does the engine just stops while warming up, and then difficult to start? You need to narrow down the problem to either fuel supply or injector signal. Try spraying Quick Start thru the FPR vacuum port to see if it will start right after warm up/stop. You can also try jumping the electrical fuel pum...

To clean the combustion chamber, just go to the local Ace hardware and buy a 1" Dia. wire bush, made from (((.009" wire))) set in a cap with a 1/4" shaft. The fine wire can clean the surface, without leaving marks in the aluminum when using a die grinder or drill motor. The only place...

J565c-4.17 Mounting height- The center of the device lens shall be mounted no less the 24 in. (610mm) above the road surface. But there has to be a lot of vehicles on the road with lites lower then 24". My guess, there is not to many states actually look at enforcement? When my vehicle was insp...

Search Cometic gaskets. They have several thinner or thicker MLS head gaskets for the 4AGE. If you want to use a Dremel tool to de-burr, use one of the small sanding drums. Or just use sand paper to knock off the burrs. Less chance of screwing up the head surface. You just need to do a really good j...

The grounding location on the intake manifold is common for all 4 of the injectors. If its a good ground for 2 injectors, it should be OK for the other 2 injectors. It is must likely a bad plug pin or wire. You are going to have to check each wire run to find the problem.
Davew7

The odds are low, but the problem could actually be the crimp in jondee86's photo or pin/plug connectors. I had increase resistance at a brass crimp where several sensor wires tee'd into a common ground wire. That is why I commented on solidering these 30 year wire joints. You have to check every wi...

Since you have the red-black wire striped back to the tee connection, Use a VOM [preferred] or continuity lite with a long test lead and verify that the red wire with the black trace, that runs to the ECU plug is good. There could be a break or enough resistance to screw up the engine ECU. You may w...

The electrical signal to the injector is so short that most VOMs will not register the signal. Go to you local auto parts and ask for a noid light. They are only a few bucks, and will verify the injector signal. davew7

Your plan sounds like a reasonable build. The only thing not mentioned was your ignition system. You will need a stand alone ignition system that will handle higher revs then a stock big port ECU. You will just need a few $$$ for your budget. davew7