I know this is long overdue, but I wanted to thank everyone for their advice and guidance. I hope this post has helped some others with their fuel related issues. I’d like to run through what actions I took to tackle the problem (over the last 2 years in between deployments).
• First, I followed the fuel line routing to ensure they were not being overheated by the exhausts system. Good to go.
• The EGR was not sticking and I went ahead and pulled the exhaust manifold and replaced the gasket.
• Fuel filter was GTG.
• The gas cap is not of the vented type, since the tank vents through charcoal canister.
• The choke may have been sticking, in hindsight.
In the end, I decided to ditch the Carter and upgrade to a Howell TBI setup. Glad I did, but that’s not the end of the story. After install, the jeep ran phenomenally… for a week. She ran exceedingly well on short trips, but any longer trip lasting for more than 15-20 minutes would cause a ridiculous amount of pressure to build in the gas tank and the jeep would run extremely rough. I dropped the gas tank and found a return line crimped between the tank and frame. The CJ had been rear ended before all this started and the collision repair guys dropped the tank to replace the skid plate.
What I can say is that I learned a lot in the process and, for my frustrations; I got a Howell TBI out of it – which is outstanding IMO. And the lesson learned is NEVER LET ANYONE ELSE WORK ON MY CJ BUT ME (with the sound technical advice of this forum, of course).