Chrysler documentary shows development of the K-Car

Horsepower might be sold. But it wasn’t always about making money. Chrysler certainly had its high-volume hits, but as many manufacturers have discovered at different times in history, they realized that small, affordable, economical cars were also important. As the 1980 video below shows, the “K-Car Superstar” was a mid-size car.

Chrysler not only needed to develop an improved successor to its L-series front-wheel-drive models, but also needed to produce a car that could compete with Japanese imports. They began to formulate goals for the new two-door, sedan, and wagon K-model cars in early 1977:

• Spacious interior space and comfort
• Precise driving and control
• Significant fuel savings
• Excellent overall quality
• Aerodynamic styling

Once development began, Chrysler built full-scale models, then used computer-controlled scanners to map the models, and then converted those scans into blueprints. The final body shape was honed in a wind tunnel, reducing drag by 20 percent over the previous model. As part of durability testing, the company subjected the suspension hardware to thousands of miles of compression and rebound testing on computer-simulated roads.

The new K-model required a new engine designed specifically for the front-wheel-drive layout. Chrysler developed a transverse 2.2-liter four-cylinder engine with a cast-iron block, aluminum heads, a cast-iron crankshaft, and a two-chamber carburetor with an electric choke. An electronic engine control unit with a microcomputer made adjustments based on readings from sensors that monitored conditions such as air temperature, engine load, and engine speed to optimize fuel economy, which Chrysler hoped to achieve at 41 miles per gallon on the highway. To make it easier to service components such as the spark plugs and fuel pump, engineers tilted the engine about 12 degrees.

Chrysler’s next challenge was to modernize its production facilities to produce its new rival to its Japanese rival. The company reportedly spent hundreds of millions of dollars updating its three plants to do the job. Computers again aided the process, in part by helping robots spot weld body panels and assemble the unibody with more than 3,000 welds. (The unexpected 3.5-minute music video at the end of the documentary? It was made with humans, the new K-model, and a little country music inspiration.)

Was all the time and money Chrysler invested in the K-car worth it? If you or someone you know owns one, let us know how it goes in the comments below.