Dodge Aspen, Plymouth Volare Repair and Service Manual 1976-1980

OVERHAUL

SOLENOID AND BRUSH SERVICE

1. Remove the starter from the car and support the starter gear housing in a vise with soft jaws.



2. Remove the two thru-bolts and the starter end assembly.



3. Carefully pull the armature up and out of the gear housing and the starter frame and field assembly.



4. Carefully pull the frame and field assembly up just enough to expose the terminal screw (which connects the series field coils to one pair of motor brushes) and support it with two blocks.



5. Support the terminal by placing a finger behind the terminal and remove the terminal screw.



6. Unwrap the shunt field coil lead from the other starter brush terminal. Unwrap the solenoid lead wire from the brush terminals.



7. Remove the steel and fiber thrust washer.



8. Remove the nut, steel washer, and insulating washer from the solenoid terminal.



9. Straighten the solenoid wire and remove the brush holder plate with the brushes and solenoid as an assembly.



10. Inspect the starter brushes. Brushes that are worn more than one-half the length of new brushes or are oil-soaked should be replaced.



11. Assemble the starter using the reverse of the above procedure. When resoldering the shunt field and solenoid leads, make a strong, low-resistance connection using a high-temperature solder and resin flux.

CHOKE UNLOADER (See Figure 11)

1. Hold the throttle valves wide-open and insert the specified gauge between the upper edge of the choke valve and the inner wall of the air horn.



2. Place slight pressure against the control lever and attempt to remove the gauge. There should be a slight drag as the gauge is being withdrawn. If adjustment is necessary, bend the unloader tang on the throttle lever until the correct opening has been obtained.

MODEL 2245 (See Figure 12)

The model 2245 carburetor is a two-barrel unit used on 360 cubic inch engines. The carburetor uses four fuel metering systems.

1. The Idle and Idle Enrichment System provides the correct mixture for idle and low-speed performance.



2. The Accelerator Pump System furnishes additional fuel during acceleration.



3. The Main Metering System gives an economical mixture for normal cruising conditions.



4. The Power Enrichment System enriches the mixture when high power output is desired.

FLOAT LEVEL (See Figures 13 and 14)

1. Invert the air horn so that the weight of the float is forcing the metering needle against its seal.



2. Measure the distance from the top of the float and the float stop. The clearance should be the same as given in the "Specifications" chart. Make certain that the gauge is level when making the measurement.



3. If adjustment is necessary, bend the float adjusting tab toward or away from the needle. A narrow-bladed screwdriver may be used to bend the tab.



4. Check the float drop by holding the air horn upright. The bottom edge of the float should be parallel to the underside of the air horn. If an adjustment is necessary, bend the tang on the float arm.

• Tune-up and routine maintenance
• Engine and overhaul procedures
• Cooling, heating and air-conditioning systems
• Fuel and exhaust systems
• Engine electrical systems
• Emissions control systems
• Transmission
• Brakes
• Suspension and steering systems
• Body
• Chassis electrical system
• Wiring diagrams