Carter WO 101 Carter WO – 101
Contents
1. ul j lj passageway gt A Lie Metering orifice and Here the metering orifice is Idle jet ce passageway inside fuel installed in the fuel bowl bowl Congratulations You have finished the main body continue back to top Visitors since January 26 2004 Copyright Richard N Meagley Sr Last revised May 25 2007 Reassembly Main Body to Throttle Body Home Up Carter WO 101 Parts Kits Tools Disassembly Cleaning and Inspection Reassembly Throttle Body Reassembly Main Body Reassembly Main Body to Throttle Body Reassembly Bowl Cover Reassembly Air Horn Installiation and things to watch for Carter Bulletin Assemble the Main body to the Throttle body We are now ready to assemble the Main Body to the Throttle Body There are two gaskets a spacer and 2 screws Actually quite simple Click on pictures for a larger version coo z e s b gt i i x Body with 2 gaskets and _ One gasket installed Spacer installed Second Gasket installed 2 screws and the assembly spacer is complete Set this sub assembly aside and we will start on the bowl cover continue back to top Visitors since January 26 2004 Copyright Richard N Meagley Sr Last revised May 25 2007 Reassembly Bowl Cover Home Up Carter WO 101 Parts Kits Tools Disassembly Cleaning and Inspection Reassembly Throttle Body Reassembly Main Body Re2. Parts Kits Tools Disassembly Cleaning and Inspection Reassembly Throttle Body Reassembly Main Body Reassembly Main Body to Throttle Body Reassembly Bowl Cover Reassembly Air Horn Installiation and things to watch for Carter Bulletin Tools You will need tools to rebuild the Carter WO carburetor There is only one special tool required The rest are either common tools or easily made from common tools There is one item that is highly recommended that is a Factory Service Manual These are available as a reprint for your vehicle from the various Willys sources The float setting gauge can be anything 3 8 0 375 I used a 3 8 lathe tool bit but a non worn down 3 8 drill shank works well also The special straight shank screw drivers can be made from a regular screw driver by grinding off the wedge Be careful fit the screw driver to the inside diameter of the screw threads with a little clearance but not so much as to allow the flat to not drive both sides of the jet or screw The one special tool required is a metering rod gauge This is available from The Carburetor Shop or can be made from the sketch I have provided Accuracy is very important when this is made Carter probably manufactured this within 0 001 A skilled machinist should be able to make this from the sketch provided Click on pictures for a larger version Full assortment of tools used Left to right 2 screw holdi
3. for Carter Bulletin Cleaning After disassembling the carb I wire brush each part to remove any loose debris organize all parts Then place the parts in the basket and dip in carb cleaner I got my carb cleaner from NAPA it was about 15 Normally 20 min to 30 minutes is all that is required to dissolve the crud As directed on the can rinse the part off with water I then blow the part dry with compressed air When the parts are dry I use wire brushes to dislodge any buildup that remains and it s back to the dip tank for a final cleaning Remember this is a carburetor and cleanliness is a must Click on pictures for a larger version Carb Cleaner Comes with dip These are idle air bleeds I am not Throttle Body and associated parts basket sure of their size but I blow out with compressed air and insert a drill to assure they are clear RF fa Here the parts after cleraning Air Horn and Main body and associated parts associated parts back to top Inspection Visually inspect all parts for wear debris and breakage Throttle shaft and choke shaft will probably have some shaft play in them The proper thing would be to remove the throttle and or choke plate s and have bushings installed For most of us this is out of our league and replacement of the carburetor is the best option Unless the shaft play is obviously excessive or you have the ability to install bushings yourself I wouldn t consider fixin
4. there were no instructions in the rebuild kits I referred to my Factory Service Manual FSM for disassembly I start from the top air horn and work my way down to the base throttle body Being very careful to place all parts in an organizes manner Even though this is a single venturi one barrel there are a lot of small parts Click on pictures for a larger version Here are the tools I used A This spring actually opens This shows how the choke During disassembly note __ Inside the fuel feed port is good set of screw drivers is the choke plate spring is installed how things were the end of the seat required assembled portion of needle amp seat saan During disassembly look Good gasket deformed This is the idle jet itis fed Fuel flows up the idle tube These are the accelerator for problems like this gasket from the bottom of the pump check valves gasket that probably was bowl leaking This is the accelerator Main jet and backup screw Parts asociated with Parts associated with Parts associates with pump discharge nozzle Notice copper gasket Air Horn main body the throttle body around main jet Cleaning and Inspection Home Up Carter WO 101 Parts Kits Tools Disassembly Cleaning and Inspection Reassembly Throttle Body Reassembly Main Body Reassembly Main Body to Throttle Body Reassembly Bowl Cover Reassembly Air Horn Installiation and things to watch
5. 2004 Copyright Richard N Meagley Sr Last revised May 25 2007
6. Carter WO 101 Home Up Carter WO 101 Parts Kits Tools Disassembly Cleaning and Inspection Reassembly Throttle Body Reassembly Main Body Reassembly Main Body to Throttle Body Reassembly Bowl Cover Reassembly Air Horn Installiation and things to watch for Carter Bulletin Carter WO 101 The Carter WO comes in two models 596S on CJ2As before SN212110 and 636SA on later CJ2As and all CJ3As There are some differences but there are insignificant to this article This carburetor is very simple as far as carburetors go There are only five circuits However as with all carburetors it is a precision device and needs to be handled as such To allow for an easier understanding of the carburetor as a whole This article will discuss the circuits individually The five circuits are float circuit low speed circuit and high speed circuit accelerator pump circuit and finally the choke circuit To enhance our understanding of carburetor operation we must understand that the fuel in the fuel bowl is at atmospheric pressure This pressure is about 14 7 pounds per square inch absolute PSIA The engine and venturi of the carburetor creates a low pressure The atmospheric pressure actually pushes the fuel up passageways into the throat of the carburetor where it is mixes with air to create a combustible mixture The proportions of this mixture are critical and the carburetor s job is to kee
7. air flowing through the venturi The correct amount of fuel required by the amount of air flowing through the throat is controlled by the taper of the metering rod The metering rod is inside the metering rod orifice and tapered so as the throttle is opened wider more fuel passes through At wide open throttle WOT only the small tip of the metering rod is inside the metering rod orifice Accelerator Pump Circuit Pump Arm and Collar Ass y Pin Spring Pump Operating Lever Assy Motering Rod Spring Throttle Connector Rod Connector Link enn iw Sila Plug Gasket Bowl Cover Goskot amaga Mig H Pump Jot Metering Rod Discharga Disk Chock Assy Plungor and Red Ass Body Flange Gasket Plunger Spring Insulator Purnp Spring Body ange Gaskot Intake Ball Check Ass y Pump Check Strainer Strainer Plug and Garkot Ass y Throttle Valve Throttle Connector Red THE PUMP CIRCUIT The accelerator pump circuit performs two functions These include additional fuel during starting and additional fuel when accelerating quickly During the engine starting operation the intake vacuum is quite low Therefore neither the low speed nor the high speed circuits can supply an air fuel mixture When depressed before starting the engine the accelerator pump supplies a small amount of fuel to the intake manifold where the vapors are pulled into the cylinders during the cranking operation This along with the choke circuit de
8. assembly Main Body to Throttle Body Reassembly Bowl Cover Reassembly Air Horn Installiation and things to watch for Carter Bulletin Bowl Cover This contain all except for the idle mixture screw the adjustments necessary on this carburetor They are the float and metering rod position Click on pictures for a larger version This is the accelerator Accelerator pump plunger Link is held on with this Accelerator pump is now _ This is the metering rod pump parts and metering installed with link showing clip installed onto bowl cover spring Notice the spring rod the pump drive spring goes through the hole in the metering rod Clip holds the metering rod on the pin The spring holds Before setting metering This is the special tool Here is the accelerator Here the accelerator pump the metering rod rod back out the throttle resting in the metering pump spring spring is installed down against the stop screw to allow the orifice It will be used to set pin and allows the throttle plate to seat in the the position of the metering metering rod to closed position rod pin float up when it contacts the metering jet the metering rod setup pump linkage It also and attach with a hair pin __ linkage on the throttle holding the throttle closed gauge Assemble the bowl moves the metering rod clip linkage and hold in place __ and the pin against the cover and gasket to the with the spring clip meteri
9. d be useful All pictures on this page are links to a larger version Just click on the photo to view and use your browser s back button to return Carter W O 101 a primer on how it works In the beginning The parts kit Tools The disassembly The cleaning The inspection The reassembly Throttle body Main Body Main Body to Throttle Body Bowl Cover o Air Horn O O 0 O e Installation and things to watch for e What to watch out for o Needle and seat e Tips and tricks e Carter Bulletin with repair pages In the beginning purchased the vehicle in good running condition and a rebuild wasn t absolutely necessary However I wanted to write a web page on the subject and thought rebuilding it would be a good idea Below are some pictures before the rebuild These were documentation photos for reference incase I forgot where something went Click on pictures for a larger version x gt E lt A T rT Front view Carter fuel filter attanhad Rear Carter filter is really a annnwvatian haul Senne k Br a gt _ EE Carb installed on engine Engine side Linkage continue back to top back to projects Visitors since January 26 2004 j x ei 5 a Copyright Richard N Meagley Sr Last revised May 25 2007 Parts Kits Home Up Carter WO 101 Parts Kits Tools Disassembly Cleaning and Inspection Reassembly Throttle Body Reass
10. d of the main jet is flush This holds the main jetin and backup screw install from bottom of main body The flats align with mating with the venturi place and causes the seal to the backup screw and new flats in the passageway seal Tighten securely but gasket Gasket seals inside don t damage drive slots d Veet 1 Accelerator pump jetand Here the accelerator pump Notice this cover screw has Accelerator pump jet cover Accelerator pump check installiation location is installed Viewed from ja tapered seal and doesn t screw installed valves screen and cover the bottom require a gasket This carb plug ready for installation had two of this style cover screw p we a This is the accelerator Accelerator pump screen This is the way the screen Here is the two accelerator Accelerator pump cover pump screen on a J drill to installed in cover screw will be once installed check valves and screen as screw installed assure a round screen priot they will function in the to installiation carb Idle jet and passageway Here is the idle jet installed This long skinny tube is the This shows the idle tube After the idle tube is This feeds from the lower before the Idle tube is idle tube It is pointing to installed and the cover installed you can see both portion of the fuel bowl installed it s passageway screw is laying on the the idle jet and the end of bench the idle tube in the idle jet
11. e attached to the knob in the driver s compartment A connector link is attached to the choke linkage and throttle linkage During starting the engine needs a fuel rich mixture When the choke is closed all vacuum produced by the engine is trapped in the carburetor throat This enables both the low speed and high speed circuits to provide fuel thus in richening the mixture The connector link between the choke linkage and the throttle link opens the throttle slightly to enhance the vacuum above the throttle plate Upon starting the cold engine continues to require a fuel rich mixture The choke continues to enhance the vacuum in the carburetor throat where by a fuel rich mixture continues A bypass on the choke plate to restricts the vacuum that can be applied continue back to top back to Rebuilding a Carter WO Visitors since February 2 2004 Copyright Richard N Meagley Sr Last revised May 25 2007 Carter WO Rebuild Home Up No Spark 24 Volt from 12 Volt conversion system D25 Cross Shaft Removal DANA 25 Grenaded Dana 41 2 Axle Replacement Carter WO Rebuild OQneWireAlternator Broken Exhaust Manifold Stud Repair ShackleReversal Main Valve Keeper Installiation Tool Carter WO Rebuild This will follow the rebuild of a Carter model WO as found on Willys L134 engines This carb is from a 1953 CJ3A but any Carter WO is similar enough that this information shoul
12. embly Main Body Reassembly Main Body to Throttle Body Reassembly Bowl Cover Reassembly Air Horn Installation and things to watch for Carter Bulletin Parts kits purchased two rebuild kits I have previously used the kits from The Carburetor Shop and have been very happy with them However this time I also purchased a kit from Krage Motor Sports Both kits were supplied without instructions or a metering rod gauge If you have a Factory Service Manual the instructions are quite good However without the metering rod setting gauge the metering rod can t be set properly and this is a major problem The kit from The Carburetor Shop is made in the U S A and of excellent quality and would do for most rebuilds I have done One item that would be nice to include is the base gasket with diffuser The kit from Krage Motor Sports is an Omix Ada and probably made off shore However it is considerably more complete If you are going to bring one back from the dead or need to install bushings for the throttle or choke this kit has the throttle and choke plate screws One obvious omission from this kit is the Idle Mixture adjustment screw This screw sometimes gets damaged by a mechanic over tightening it Click on pictures for a larger version The Carburetor Shop Rebuild Kit Krage Motor Sports Master Rebuild kit continue back to top Visitors since January 26 2004 Tools Home Up Carter WO 101
13. ens the bumps found when driving off road Fuel pressure plays an important part in the fuel level also Too much pressure will cause a high fuel level and too little pressure will provide too low of a fuel level A low fuel pressure could also be insufficient to provide the fuel required by the engine Stalling could occur The size of the orifice in the needle and seat assembly also effects the fuel level Too large of an orifice will act like too much pressure and too small of an orifice will act like too little pressure This is covered in detail here Low Speed Circuit Choto Valve Idle Blood By pass Low Speed Passage Plug and Goskot Ass y Bowl Cover Gaskot a Economizer Low Spoed Jet Idlo Woli Jot m l Idle Adiustmoat Scrow SS Idle Ac ent Screw Spring Idle Port Rivet Plug Throttle Valve THE LOW SPEED CIRCUIT The low speed circuit is sometimes called the idle circuit This circuit provides fuel to the engine from idle until the high speed circuit kicks in at about 20 mph The low speed circuit actually supplies some fuel during the operation of the high speed circuit The significance of this is very small after the high speed circuit begins to operate Intake manifold vacuum causes fuel from the fuel bowl to flow through the idle well jet and up the low speed tube Air enters through a throttle plate bypass port and mixes with the fuel creating a fuel rich air fuel mixture This mixture flows thr
14. g the shaft play If shaft play is required to be fixed then I suggest calling The Carburetor Shop for an estimate on repair I use a number drill set to check for clean jets These drills have never seen a drill chuck as I use the shank size to check the orifice The FSM defines the orifice sizes I use compressed air and the shank end of the drill Blow air through and slide the drill through Always start with a drill 1 or 2 sizes smaller and work your way up to be sure you don t damage the orifice NEVER FORCE the drill shank through the orifice If a drill a couple sizes smaller won t slide through or air won t go through it s back to the solvent tank for a while If you some how break a drill off in a jet replace the jet Once all parts are clean and ready for reinstallation then and ONLY then start reassembly continue back to top Visitors since January 26 2004 Copyright Richard N Meagley Sr Last revised May 25 2007 Reassembly Throttle Body Home Up Carter WO 101 Parts Kits Tools Disassembly Cleaning and Inspection Reassembly Throttle Body Reassembly Main Body Reassembly Main Body to Throttle Body Reassembly Bowl Cover Reassembly Air Horn Installiation and things to watch for Carter Bulletin Reassembly Throttle Body Now the parts are all clean you know what new parts you are going to be used and everything is organized for assembly What the previous
15. ide the choke to throttle linkage __ Install the spring inder the choke support and install the choke onto the throttle first then onto the end and hold in place with a hair Opening spring choke end pin clip continue back to top Visitors since January 26 2004 Copyright Richard N Meagley Sr Last revised May 25 2007 Installiation and things to watch for Home Up Carter WO 101 Parts Kits Tools Disassembly Cleaning and Inspection Reassembly Throttle Body Reassembly Main Body Reassembly Main Body to Throttle Body Reassembly Bowl Cover Reassembly Air Horn Installiation and things to watch for Carter Bulletin Installing on the engine Before installing on the engine set the idle mixture screw at a setting that will allow the carburetor to function This is 1 2 turns from fully seated Turn in the idle mixture screw till it stops and then back out 1 1 2 turns Also set the idle speed screw at a position the should allow the engine to idle This is two 2 turns after the screw begins to open the throttle When installing on the engine be sure to use new gasket s either the diffuser gasket or a thickness equivalent This thickness is required to prevent the carb hold down studs from contacting the carb body and preventing a seal back to top Things to watch out for Click on pictures for a larger version back to top back to projects Visitors since January 26
16. ng rod gauge tighten bowl and tighten securely ignore wrench for now This is the pin resting on This is the accelerator Install the linkage as shown Install the accelerator pump Ok here goes While the nut on the pin er put Sie alle J nd get The 3 piece needle is ready to install and set the shown in assembly opder float springloaded ik Werks needle Note Gasket NOT installed Here are the float parts This tang is bent slightly to Once the float is set install Install metering rod as position the float at the gasket previously shown reinstall precisely 3 8 from bowl bowl cover cover without gasket continue back to top Visitors since January 26 2004 Copyright Richard N Meagley Sr Last revised May 25 2007 Reassembly Air Horn Home Up Carter WO 101 Parts Kits Tools Disassembly Cleaning and Inspection Reassembly Throttle Body Reassembly Main Body Reassembly Main Body to Throttle Body Reassembly Bowl Cover Reassembly Air Horn Installiation and things to watch for Carter Bulletin Air Horn All the hard work is done Next we assemble the air horn Click on pictures for a larger version Here is the Air Horn ready for When the air horn is Here is the choke amp throttle cable installiation installed be careful of support the accelerator pump and metering linkage Install the choke amp throttle cable Sl
17. ng screwdrivers Drawing of home made metering rod regular screw driver 2 straight shank screw seting tool drivers 2 small wire brushes continue back to top Visitors since January 26 2004 Copyright Richard N Meagley Sr Last revised May 25 2007 Disassembly Home Up Carter WO 101 Parts Kits Tools Disassembly Cleaning and Inspection Reassembly Throttle Body Reassembly Main Body Reassembly Main Body to Throttle Body Reassembly Bowl Cover Reassembly Air Horn Installiation and things to watch for Carter Bulletin Disassembly Remove the carb from the engine and determine what pieces are included in the rebuild kit you will use I used the Carburetor Shop kit This kit includes the accelerator pump check valves idle jet metering jet and the accelerator pump plunger return spring It also includes all the gaskets and seals needed Next assemble the tools you will need to do the job I have some screw drivers that I have ground to just slip into the holes where the juts are located In addition to the tools shown below I use a number drill set to check orifice sizes These drill ONLY are used for checking hole size and never drilling holes I disassembled the entire carb This ISN T necessary All the jets can be cleaned and checked for size without removal I would suggest only removing what you will replace unless there is a specific reason for removal In as much as
18. ough an orifice known as the economizer It continues past the air bleed and down to the idle port and idle adjustment needle opening The idle mixture adjustment screw provides the adjustment necessary at idle The idle port is a slot that is partially covered by the throttle plate Air from the top of this slot mixes with the air fuel mixture and finally achieves the correct proportions for combustion As the throttle plate is opened more of the slot is exposed This allows more of the fuel rich mixture to flow into the engine and the increased air allowed by the open throttle plate leans the mixture to the correct proportion This increase continues until the high speed circuit can take over Actually the idle circuit continues to provide a small amount of fuel through the operation of the carburetor High Speed Circuit Choke Valve Pin Motoring Rod Pin Hex Nut Metering Rod Fin Motoring Rod Pin Washer Matering Rod Spring Nozio Gasket Nozzle Retainor Plug Metoring Rod Metering Rod Jot and Gasket Ass y Nozzlo Passage Plug and Gotkot Ass y Nozle Throtile Vaive 5 THE HIGH SPEED CIRCUM The high speed circuit begins to operate at about 20 mph At this point the velocity of air passing through the venturi of the carburetor reduces the pressure at the main nozzle and fuel begins to flow through the metering rod orifice It continues past the metering rod and out the main nozzle where it mixes with the
19. p them optimum To achieve these optimum proportions the orifices or jets in the carburetor are calibrated by the factory The orifices must be kept at their designed size for the carburetor to perform its function optimally Float Circuit ER i Bowl Cover and Pin Ass y Noodle and Soat Ass Intake Needle Spring Bowl Cover Gasko Intake Needle Pin Float Lever Pin Float and Lever Ass Noedlo Seat Gasket ry 14 THE FLOAT CIRCUIT The float circuit controls the fuel level in the carburetor bowl If the level is too high excessive fuel will be provided and the mixture will be too rich Conversely too low of a level will cause the mixture to be too lean Both of these will lead to poor performance and can be taken to the extreme An extremely high fuel level can cause raw fuel to spill into the venturi at idle causing flooding An extremely low fuel level will result in the negative pressure at the end of the nozzle being insufficient to pull enough fuel from the bowl to allow the engine to do anything but Idle Fuel enters the fuel bowl through a valve called a needle and seat The needle is pressed against the seat by the float to shut off fuel When the fuel level drops to a level where the needle moves away from the seat fuel enters the bowl until the needle moves to the seat thus shutting off fuel The needle assembly is a three piece device consisting of a pin spring and needle The float actually presses the pin and the spring damp
20. scribed later assists in engine starting When the throttle is opened the high speed circuit reaction time doesn t react as quickly as required The accelerator pump provides increased fuel to the throat of the carburetor during these critical times Operation of the accelerator pump is a simple pump circuit consisting of a spring return cylinder two check valves a discharge nozzle and spring to prolong the flow When the throttle is opened the cylinder rod is forced down forcing fuel in between the check valves The intake check valve closes and the exhaust check valve opens allowing fuel to flow up to the discharge nozzle in the carburetor throat When the throttle 1s opened more quickly than the circuit can discharge fuel the spring acts to prolong the fuel flow This precisely what the high speed circuit requires due to it s relative slow reaction time When the throttle begins to close the cylinder reverses it s movement closing the exhaust check valve and opening the intake check valve Fuel then flows from the bottom of the bowl through a filter screen to recharge cylinder for the next operation Choke Circuit The choke circuit is used in starting and warming up a cold engine by providing a fuel rich mixture to the engine _ The components of the choke circuit include the choke plate mounted on a shait and a lever at one end A spring attached to the lever is actuated by the choke linkage controlled by the choke cabl
21. sentence is not true STOP Do what is required to make that sentence true OK Now you are ready for assembly In as much as I started disassembly with the air horn and finished with the throttle body Let s start assembly with the throttle body proceed to the main body then the bowl cover and finish with the air horn Click on pictures for a larger version This is the trottle body and the associated parts If you have The parts are assembled as shown Turn the idle mixture a vacuum adviance distributor the 1 8 pipe plug will be a adjustmet screw in all the way and back it out 1 1 2 turns vacuum fitting That s a good starting place Set the throttle body aside and on to the main body continue back to top Visitors since January 26 2004 Copyright Richard N Meagley Sr Last revised May 25 2007 Reassembly Main Body Home Up Carter WO 101 Parts Kits Tools Disassembly Cleaning and Inspection Reassembly Throttle Body Reassembly Main Body Reassembly Main Body to Throttle Body Reassembly Bowl Cover Reassembly Air Horn Installiation and things to watch for Carter Bulletin Main Body The main body is where most of the action is Click on pictures for a larger version The large hole is the main Main jet Notice angle cut Notice the angle cut on the Main Jet backup screw After installing Main jet jet passageway viewed on end flats and washer jen
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