Dodge Aspen/Volare 1976-1980 Repair Guide

Distributor

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Fig. Fig. 1 Exploded view of the 225 cu. in. 6-cylinder engine ignition distributor. Lean Burn models would have an additional pick-up and no vacuum control unit



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Fig. Fig. 2 Exploded view of the 318 and 360 cu. in. 8-cylinder engines ignition distributor. Lean Burn models would have an additional pick-up and no vacuum control unit



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Fig. Fig. 3 To remove the distributor, first disconnect the vacuum hose then the wiring harness plug



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Fig. Fig. 4 Remove the cap and mark the rotor and distributor position. Loosen the hold-down bolt ...



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Fig. Fig. 5 ... then remove the clamp and bolt



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Fig. Fig. 6 Pull the distributor straight out to disengage it from the engine

REMOVAL



  1. Disconnect the vacuum advance line(s) at the distributor.
  2.  
  3. Disconnect the lead wire at the harness connector.
  4.  
  5. Unfasten the distributor cap retaining clips and lift off the cap.
  6.  
  7. Mark the distributor body and the engine block to indicate the position of the body in the block. Scribe a mark on the edge of the distributor housing to indicate the position of the rotor on the distributor. These marks can be used as guides when installing the distributor.
  8.  
  9. Remove the distributor hold-down clamp screw and clamp.
  10.  
  11. Carefully lift the distributor out of the block. Note the slight rotation of the distributor shaft on a six as the distributor is removed. When installing the distributor the rotor must be in this position as the distributor is inserted into the block.
  12.  

INSTALLATION



Engine Not Disturbed
  1. Install a new seal in the groove of the distributor shaft and carefully lower the distributor into the distributor bore.
  2.  
  3. With the rotor positioned slightly to the side of the mark on the distributor body, engage the distributor drive gear with the camshaft drive gear on a six. As the distributor slides into place the rotor will rotate slightly and align with the mark on the body. On a V8, engage the distributor shaft tongue with the oil pump drive gear slot.
  4.  
  5. Install the distributor hold-down clamp and bolt. Do not tighten.
  6.  
  7. Install the distributor cap and coil primary wire or lead wire.
  8.  
  9. Set the point gap where necessary and time the engine.
  10.  
  11. Tighten the distributor hold-down clamp and install the vacuum advance hose.
  12.  

Engine Disturbed

If the crankshaft has been rotated or otherwise disturbed (as during engine rebuilding) after the distributor was removed, proceed as follows to install the distributor.

  1. Bring the No. 1 piston to TDC by removing the No. 1 spark plug and inserting a finger over the hole while rotating the crankshaft. The compression pressure can be felt as the No. 1 piston approaches TDC on the compression stroke. The TDC timing mark on the crankshaft vibration damper should now be opposite the indicator on the timing chain case.
  2.  
  3. For six-cylinder engines: Align the distributor so that the rotor will be in position just ahead of the distributor cap terminal for the No. 1 spark plug when the distributor is installed. Now lower the distributor into its engine block opening, engaging the distributor gear with the camshaft drive gear. Be sure that the rubber O-ring seal is in the groove in the distributor shank. When the distributor is properly seated, the rotor should be under the No. 1 distributor cap terminal. Proceed with step 4.
  4.  
  5. For eight-cylinder engines: Clean the top of the engine block around the distributor opening to ensure a good seal between the distributor base and the block. Align the distributor so that the rotor will be in position directly under the distributor cap terminal for the No. 1 spark plug when the distributor is installed. The slot in the drive gear should point to the first intake manifold bolt on the left side. Lower the distributor into its engine block opening, engaging the tongue of the distributor shaft with the slot in the distributor and oil pump drive gear.
  6.  
  7. Install the distributor hold-down clamp and tighten its retaining screw finger-tight.
  8.  
  9. Replace the distributor cap. Connect the primary wire to the coil or the lead wire to the harness.
  10.  
  11. Connect the vacuum advance line to the distributor.
  12.  
  13. Check the ignition timing.
  14.  

AIR GAP ADJUSTMENT





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Fig. Fig. 7 Pick-up coil air gap adjustment. Place the feeler gauge between the reluctor and the pick-up coil

Lean Burn engines (first generation system) have two pick-up coils. The start pick-up has a larger connector than the run pick-up. The two pick-ups have different air gaps, but are adjusted in the same manner. On some 1980 models, the start pick-up has a dual prong male connector; the run pick-up has a male and female connector.

Single pick-up distributors follow steps 1-7 only. Steps 8-10 are for dual pick-up distributors.

  1. Align one reluctor tooth with the pick-up coil tooth. On dual pick-up models, align the reluctor tooth with the start pick-up coil tooth.
  2.  
  3. Loosen the pick-up coil hold-down screw.
  4.  
  5. Insert a non-magnetic feeler gauge between the reluctor tooth and the pick-up coil tooth. The gauge should be 0.008 in. through 1976, 0.006 in. 1977 and later.
  6.  
  7. Adjust the air gap so that contact is made between the reluctor tooth, the feeler gauge, and the pick-up coil tooth.
  8.  
  9. Tighten the pick-up coil screw.
  10.  
  11. Remove the feeler gauge.
  12.  

No force should be required to remove the gauge.

  1. Check the air gap with a non-magnetic feeler gauge: 0.010 in. through 1976, 0.008 in. l977 and later. The gauge should not fit into the air gap.
  2.  


WARNING
Do not force the feeler gauge into the air gap.

  1. On dual pick-up models, align one reluctor tooth with the run pick-up coil tooth. Loosen the pick-up coil screw. Insert a 0.012 in. non-magnetic feeler gauge between the reluctor and pick-up coil, and move the pick-up coil against the feeler gauge, as in Step 4.
  2.  
  3. Tighten the screw and remove the gauge. No force should be required to remove the gauge.
  4.  
  5. Check the air gap with a 0.014 in. non-magnetic gauge. The gauge should not fit into the air gap.
  6.  


WARNING
Do not force the feeler gauge into the air gap.

 
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