Toyota Repair: engine dies, air flow meter, intake tubes

Question
Hey Ted,

I have a ‘84 SR5 (it is actually a Dolphin RV)  It has a 22REC engine w/ AC.  She is about 1800 miles out of a complete engine overhaul.  She ran perfect until we parker her for two years.

The problem is it starts fine, one turn of the key, and drops into a smooth idle.  When any… and I mean ANY touch of the throttle, it sputters and dies.  I changed out the gas.  I have checked the TPS, the fuel-pressure-relief-thingie and the air valve.  I replaced the entire fuel rail and the injectors.  I swapper distributors from 2 identical engines, and replaced plugs, cap rotor and wires.  I replaced the coil and igniter and checked the timing.  I even pulled the front off and visually confirmed that the timing marks line up.

After all that, it runs a tiny bit better, meaning I can tease the throttle open to about 1500 RPM.  It still dies when I put any load on it.  I’d suspect fuel problems, but I can hear the injectors clicking away with a stethoscope and pressure seems fine.  I’d suspect timing, if I hadn’t physically checked the chain, and adjusted it myself.

Any ideas?  I’m about to put my head through a wall.

--Justin


Answer
Has the fuel pressure been checked with a mechanical pressure gauge? If not, this needs to be done to confirm that there is enough fuel pressure, about 30-35 psi.
The only other thing I can think of is that for some reason the exhaust or intake system is restricted.
Check the air flow meter and make sure the door in the meter can move freely, check for any foreign objects in the intake tubes. Try another air flow meter.
The other possibility is that the catalityc converter may have become restricted, it's not probable but possible, remove the converter and see if the problem persists or goes away.