I have a KJ2 AWD, recently I changed the rocker cover seals, tube seals, spark plugs and leads.

Now it hesitates under load and sounds loud sort of like a Subaru. By load I mean anything that is not idle in park or neutral. I touched the muffler, for no reason, and it was 10 times hotter than usual.

I'm thinking this might be an ignition related problem. The leads are all clicked firmly in place.

Any ideas?

Please and thank you.

I would just recheck over everything to make sure that you installed everything correctly
Might have missed something

make sure the sparkplug leads are in the correct order, make sure there is no vacuum leaks and ,ake sure all leads are connected right.

Make sure your injector plugs are in properly. A mates commodore was doing this and turned out his injector plugs were off

Thanks guys! :D

Some of the leads had popped off the distributor slightly. I pulled them all off, reconfirmed the order and forced them on really hard bled out the air. I guess 1 in the morning wasn't the best troubleshooting time. I also lost an injector plug seal but it seems okay for now.

For anyone that has similar issues, I once put Magnecor 8mm leads onto my old car and the 1/4 mile time dropped by over half a second (confirmed over 3 runs).
I had the original 4mm leads in the car, so swapped them back and got my half second back on the next run, all on the same night.
Reason was that MRT sold me some fake leads. Not happy, Jan !!

For anyone that has similar issues, I once put Magnecor 8mm leads onto my old car and the 1/4 mile time dropped by over half a second (confirmed over 3 runs).
I had the original 4mm leads in the car, so swapped them back and got my half second back on the next run, all on the same night.
Reason was that MRT sold me some fake leads. Not happy, Jan !!

MRT sold fake leads?

yeah, this was about 1996 or so. It turned out there were two "magnecor" brands and he sold me the some. Wouldn't give any refund after I proved they were defective via my timeslips either. He also gave me a ceramic clutch on a lightened flywheel that he didn't heat treat. The soft flywheel meant that the clutch lasted about 2,000kms and left me stranded interstate on a long weekend. Repair bill was over $2k for standard parts, and all he did for me was send the clutch off for new pad material.

This was all before WRX's became popular, back when MRT was only doing Daihatsu gear. Their capability must be better now, because they are still in business and doing many cars - maybe I was a guinea pig on the bleeding edge, unfortunately it bled my wallet too mutch. The $ lost would have let me do a turbo conversion. :(

Sorry, not off topic - I was linking into the WRX sound that MRT got involved in.