1W7

Chrysler
Engineering
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Table of Contents
Page
Acrylic Dispersion Enamel ... ...XXV
Air Conditloner .... .....XXll
Alternator . ...Xll,XXl
Anti-RustProtection ....XXV
Autophoretic Treatment ... ... ..XXV
Automatic Temperature Control . .XXll
Axles, Rear .....XVll
Battery ....Xll
Body Construction . .. ... .Xxlll, XXIV
Brakes . .. ... ..XXXll
Bumper System, Hydraulic
lmpact-Absorbing .. .....V
Catalytic Converter ..XlV XV
Coolant System . ....... ..Xl
Diodes, Light-Emitting ...XXll
Disc Brakes ...XXXll
Dip-and-Spray Anti-Rust
Treatment ....XXV
Dual Braking System ..XXXll
Electronic Differential
Amplifier ......XX||
Electronic Digital Clock .. ... .. ..XXl
Page
Electronic lgnition .. .XlX-XXl
Electronic Lean-Burn System ..Vll-lx
Electronic Spark Control ... ...Vll-lx
Electronic Voltage Regulator.. .. .XXl
Electronics ..XlX-XXl
Emissions Control System ...XlV XV
Energy-Absorbing
SteeringColumn ....XXXlll
Engineering Highlights ....... .. ..lll
Engineering Leadership .. .. ....|V V
Engine Mounts ... ...... ..Xl
Engines and Engine Features .Vl-Xlll
Epoxy Primer ...XXV
Fuel Pacer System ... .. .XV
Fuel System .....XV
Gasoline Tanks . ....... ..XV
Horsepower and Torque ..... .. .. .Vl
lgnition System .Xlll, XIX-XXI
lnstrument Panel . ....XXXIV
Leaf Rear Springs .. . ..XXVIlI-XXXI
Lean-Burn System .. ..Vll-lx
Light-Emitting Diodes . ..XXll
Maintenance ..XXXV
Metric System .XXXVI
Parking Brake . . .. ....XXXll
Radios, Solid-State .. . ..XXll
Page
Rear Axles . ... ..XVll
Rubber lsolators ..XXX, XXXI
Safety Features ... . ..XXXlll
Safety-RimWheels .....Xvlll
Servicing Made Easy .XXXIV
Sound-Deadening
Materials .....XXVI,XXVII
StaderRelay. ....Xlll
Steering ... ....XXXll
Sure-Grip Rear Axle ....XVll
Suspension .....XXV|||-XXXI
llres and Wheels ..... .Xvlll
TorqueFlite Automatic
Transmission .........XV|
Torsion-Bar Front
Suspension .. .XXVlll-XXX
Torsion-Quiet Ride .. ....XXX
Transmissions . ... .... ..XVl
Unibody Construction . . . .XXlll, XXIV
Valve Seats, Exhaust .. ....X
WeightReduction .....XXXlll
1977 engineering highlights
New, more powedul lightweight battery will
be available for use with the 318 V-8 engine
(Cordoba only) for 1977. This battery has the
same heavy-duty construction used on Chrysler
Corporation's 500-ampere Long-Life battery.
The battery has a higher amperage rating and
weighs less than the previous battery standard
with these engines.
Electronic Lean-Burn System with electronic
spark control is available on more engines for
1977. This advanced system adjusts the spark
advance precisely for all driving conditions for
improved engine responsiveness, and
controlled emissions. See the story on page Vll.
Cool-air induction is used with all engines for
\
1977 . The cool-air intake directs air f rom outside 7
the car through a flexible duct to the carburetor
air cleaner. This system prevents intake air from
mixing with heated engine-compartment air,
resulting in lower inlet air temperature at the
carburetor-as much as 300F. lower on hot days.
Result: better on-the-road power on hot days.
New autophoretic anti-corrosion treatment.
Stub frames and front crossmembers are
protected against corrosion in 1977 by
Chrysler's new autophoretic chemical-coating
treatment. Parts are treated in seven stages
including a self-depositing coating system-
then baked in an oven to harden the coatings.
See the story on page XXV|l.
Low-slip torque converter tor TorqueFlite
Chrysler's TorqueFlite automatic transmission
has always had a reputation for good
pedormance. Now Chrysler engineers have
added a new low-slip torque converter designed
to improve fuel economy for both city and
suburban driving. The low-slip torque converter
is used with all TorqueFlite models and with all
engines.
Weight reduction engineering expanded
With increased emphasis on economy, Chrysler
engineers have intensified their continuing
weight-reduction program designed to remove
unnecessary weight from all Chrysler models,
regardless of size. This is being done by using
high-strength steels, lighter weight alternative
materials, which are as strong or stronger than
the heavier materials being replaced and by
redesigning parts to eliminate unnecessary
weight. Window glass, for example, has been
made thinner and lighter on some cars, while
retaining strength equal to the thicker, heavier
glass. See page XXXVllfor more complete story.
Chrysler engineering leadership
. r r gives you
features like these!
Electronic Lean-Burn
System, with its electronic
spark control, is one of the
important developments in
engine control since the 1920's
and early 30's, when manual
spark control
was replaced by the automatic
spark advance. Eight sensors
and an electronic computer
combine to adjust spark
advance precisely for all driving
conditions. See page Vll for
Lean-Burn System availability.
Double-contact starter relay
provides increased voltage for
more reliable starting,
particularly in very cold
weather. The new second
contact provides full-battery
voltage to the ignition coil
during starting.
1.8-horsepower starter
motor. This high-speed starter
is standard with all engines
having 360-cubic-inch or larger
displacements. Provides quick
starting.
Neq lightweight battery with
higher amperage than the
previous battery will be
available for use with the 318
V-8 engine. This battery has the
same heavy-duty construction
as Chrysler Corporation's
SO0-ampere Long-Life battery.
Electronic ignition. No ignition
tune-ups except a
recommended spark plug
change at 30,000 miles with
unleaded gasoline. Spark plugs
may be changed more often if
misfiring is detected in order to
preserue cleaner air. The
ignition system should function
like new for 50,000 miles.
Electronic voltage regulator,
with its solid-state components,
assures greater reliability than
the conventional regulator and
helps to increase battery life.
Every regulator is tested before
it is installed.
10O-ampere alternator is
included with the optional
electrically heated rear-window
defroster on all full-size and
intermediate-size models.
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Front disc brakes. Smooth
braking-regardless of terrain.
Standard on all Chryslers.
Torsion-bar front suspension
system contributes to
Chrysler's excellent ride
characteristics, helps control
brake dive, and is easily
adjustable for height. Standard
on all Chrvsler cars hrrilt in
Long-Lile battery.
500-ampere battery is standard
with the 440 V-8 engine,
optional at extra cost with other
engines.
Coolant reserve system. The
translucent plastic reserve tank
gives added coolant expansion
capacity, permits checking of
coolant level without removing
the radiator cap and minimizes
air in coolant to reduce
New, autophoretic
anti-corrosion treatment.
Stub lrames and front
crossmembers are treated in a
seven-stage anti-corrosion
system, which includes a
self-depositing coating and an
oven baking to harden the
coating.
Body anti-rust treatments.
7-step process protects the car
body inside and out. The lower
portion of the body is dipped in
rust-resistant primer. The sills
are galvanized.
Unibody construction.
Strength surrounds the
passengers. Body and frame
are fused into one solid unit by
more than 4,000 tough welds.
Catalytic converter. A
chemical reaction, intensified
by the catalyst, oxidizes
hydrocarbons and carbon
monoxide.
Hydraulic, impact-absorbing
bumper system. Large
hydraulic cylinders-two
mounted on the front bumper
and two on the rear
bumper-help absorb impacts.
Both systems will withstand
barrier impacts up to 5 m.p.h.
TorqueFlite automatic
transmission. Provides
smooth, quiet and dependable
operation. No recommended
maintenance under normal
driving conditions. Every
transmission is computer tested
for conformance to functional
specifications to add to its
raliahilihr
Radial-ply tires are available
in glass-belted, fiber-belted and
steel-belted versions for
Cordoba 1977. Steel-belted,
radial-ply tires are standard on
all full-size Chryslers. The
glass-belted and f iber-belted
Multi-leaf rear springs. Long,
multi-leaf rear springs help to
provide a smooth ride.
Off-center, forward mounting of
the axle helps to minimize
acceleration squat.
Domed fuel tank. The fuel-tank
dome houses a vapor-liquid
separator above the fuel level.
The separator directs fuel
vapors to the charcoal cannister
for storage. The vapors are
purged from the cannister and
consumed by the engine during
normal engine operation,
eliminating fuel vapor
emissions.
1977 Chrysler engines
Engines and specifications
NOTE: ELB means engine is equipped with Electronic Lean-Burn System
Horsepower and torque
For years, engine horsepower and torque ratings published by
the automobile industry were the maximum ratings obtainable.
They were gross horsepower and gross torque ratings.
ln 1972, the automotive industry began using net horsepower and
net torque in their publications. Net horsepower and torque ratings
are lower than gross ratings for the same engine. Here's the
difference. Gross horsepower and torque ratings are obtained at
the flywheel with optimum ignition setting (manual instead of
automatic advance) and without allowance for the power absorbed
by such engine components as the fan, alternator and car exhaust
system.
Net horsepower and torque ratings are measured at the flywheel of
the engine-but with all of the accessories (as in a car) such as fan,
alternator, automatic spark advance, and car exhaust system
installed.
Chrysler's revolution ary electronic
lean-burn system-a major
engineering breakthrough !
For example:
r
Smooth engine warm-ups.
.
lmproved engine performance and
acceleration.
.
lmproved smoothness of engine operation.
.
Controlled emissions-even before they
reach the exhaust system.
o
Less hoses and other emission-control
"hardware."
Several responsive sensors feed
information to an electronic computer
to keep the lean-burn engine
performing efficiently under all
these conditions.
1. Engine speed (r.p.m.). As engine speed
increases, spark plugs must be fired
sooner for the engine power and efficiency
needed. This sensor reads engine speed
and signals the computer to adjust spark
timing accordingly.
Chrysler's electronic lean-burn
system, with its electronic spark
control, is one of the important
developments in engine control since
the 1920's and early 30's, when
manual spark control was replaced by
the automatic spark advance. That's
because the electronic lean-burn
system contributes so many
improvements to engine operation.
5. Engine coolant temperature. This
sensor tells the computer to limit spark
advance during engine warm-up while the
choke is on. This helps control emissions.
6. Carburetor throttle open or closed. This
sensor operates a timing counter which
remembers how long and how often the
throttle is opened or closed. lt allows full
spark advance at highway speeds, but in
city driving spark advance is modulated to
control exhaust emissions.
7. Engine starting. This sensor tells the
computer when the engine has started
and advances the timing for about one
minute to cut down on engine stalls.
The electronic spark-contro! computer
responds to data from all sensors and
instantly adjusts the timing of spark-plug
firings. Since conditions are constantly
changing, the computer is constantly
making instantaneous adjustments
in spark-plug firings.
2. Engine load. This sensor signals the
computer to advance the spark for
optimum fuel economy at part throttle.
Throttle position. This electronic sensor
reads accelerator pedal position and
signals the computer to advance the spark
under conditions when speed and load
alone do not give the correct signal.
Speed of throttle movement. This
sensor signals the computer to advance
the timing briefly in anticipation of the
desired acceleration. The faster the
acceleration, the longer the duration of
extra advance. There is no lag.
4.
Some facts about1977 Chrysler engines
360 4-barrel V-8
This version of the 360 cubic-inch V-8 is designed to
meet Calilornia and high-altitude emission-control
regulations. lt DOES NOT have the Electronic Lean-Burn
System. lt is available on all models-except station
wagons.
This engine comes equipped with an air pump as well as a
catalytic converter. lt can be ordered for use at low altitudes
and outside the state of California, but only with the Ng6
emission-control package. This engine is equipped with a
single exhaust.
318 2-barrel V-8 (Cordoba only)
Chrysler's most compact V-8-designed to be
rugged and durable.
The 318 cubic-inch V-8 engine has proved its reliability over
the years as the number one seller in Chrysler Corporation's
lineup of V-8 engines. Features of the 3.18 V-8 include:
Hydraulic valve lifters (tappets)-no periodic
adjustments required.
lnduction-hardened exhaust valve seats.
Electronic ignition.
Cast nodular iron crankshaft.
Single exhaust system with catalytic converter.
Aluminized steel exhaust and tail pipes.
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Electronic Lean-Burn System is standard with Chrysler's
400 and 440 V-8 engines!
Jrder a 400 4-barrel V-8 or a 440 4-barrel V-8 and it comes equipped with
Chrysler's Electronic Lean-Burn System! The E85 440 V-8 is available in
all states, including California, and at high or low altitudes. The E64 400 V-8
is not available in California or at high altitudes.
400 4-barrel V-8 with
Electronic Lean-Burn System
The 4-barrel carburetor, large intake and
exhaust-valve ports and large 21/2"-diameler
exhaust pipe give this engine the excellent
breathing necessary for good engine
performance. This means responsive
acceleration at cruising and highway passing
speeds. A deep-skirt engine block and rugged
cast ductile iron crankshaft contribute to the
durability of this engine. Main bearings are
durable aluminum-on-steel construction.
440 4-barrel V-8 with
Electronic Lean-Burn System
This is Chrysler's biggest engine-440 cubic
inches of piston displacement-and it's the most
powerful. The combination of its large
displacement, large intake and exhaust valve
ports and manifold passages, 4-barrel
carburetor and low-restriction exhaust system
give the 440 extra power for quick acceleration
at all speeds-low, middle, or highway
cruising-or for towing large travel trailers. The
440 V-8 features a deep-skirt engine block,
rugged cast ductile iron crankshaft and
aluminum-on-steel main and connecting-rod
bearings for exceptional durability and smooth
operation.
The electronic computer of the
Lean-Burn System adjusts ignition
timing to improve many common engine
operation conditions without you ever
knowing!
For example:
1. The engine is cold. The coolant sensor tells
the computer, which retards the spark so the
engine isn't putting out a lot of pollution while
the choke is on.
2. The engine coolant warms up. The sensor
reports to the computer and the spark is
advanced.
3. The engine is started in the morning and
the car is driven away. Sensors tell the
computer lo provide spark advance to get you
going.
4. Driving up a hill or pulling a trailer. The
engine load sensor reads manifold vacuum
and tells the computer whether the engine
needs less spark advance to prevent
detonation when pulling up the hill-or more
spark advance going down the other side.
Responsive spark timing does the
job.
5. Driving on an interstate highway. The spark
is advanced for better fuel economy.
6. Rapidly depressing the accelerator. The
sensor signals the computer to instantly
advance the spark for more power to
accelerate the car. There's no lag in spark
advance like you get in ordinary engines.
1977 Chrysler engine features
Chrome-plated
exhaust-valve stems
The exhaust-valve stems on all Chrysler
engines are chrome-plated for increased
resistance to wear.
lnduction-hardened exhaust-
valve seats resist wear
Exhaust-valve seats are induction-
hardened on all engines to allow satis-
factory use of lead-free luels. ln the hard-
ening process, seats reach a temperature of
1700' F. and are then allowed to air-cool.
This hardens the valve seat surfaces to a
depth of .05" to .08" which gives them
greater resistance to wear than unhardened
seats.
Thermostatically controlled
heat valve
This heat valve is located in the right
exhaust manifold and diverts hot gases to
the floor of the intake manifold which helps
to vaporize the fuel mixture when the engine
is cold. This results in faster engine
warm-up and improves driveability after a
cold start. During warm-up, a thermostatic
spring allows the heat valve to open to the
exhaust pipe-so gas flow through the
intake manifold crossover passage ls
decreased. The heat valve is standard on all
Chrysler engines in Federal applications.
Dual concentric throttle
return springs
All 360-, 400-, 44O-cubic-inch V-8 engines
used on Chryslers have dual concentric
throttle springs in addition to a torsion
throttle spring. The dual concentric spring
system meets the Federal safety
requirements for multiple throttle return
systems.
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Staln/ess-steel swivel top
Gaskef retainer
Filler neck Radiator top tank
Cool-air induction assures
better hot-weather performance
A long, flexible air-intake duct connected to the
carburetor air intake is mounted to the radiator suppott
panel where it receives air from outside the car before
it can be heated by underhood temperatures. This
arrangement lowers carburetor air intake
temperatures by as much as 30' F. on hot days for
better on{he-road engine power. All 1977 Chrysler
engines have the cool-air induction system.
Swivel-top radiator pressure cap
Radiator caps for all Chrysler models and
engines have a swivel-top that is easy to
remove, and the caps are made of stainless
steel for anti-rust protection.
The upper gasket for the radiator cap is
rubber for good sealing. A soluble oil is added
to the coolant at the factory to retard the
formation of solder corrosion.
Coolant reserve system
A 21/z lo 41/z-quart coolant reserve tank is
standard on all Chrysler passenger cars with
both standard and optional engines. This
system eliminates coolant loss caused by
expansion of the coolant when the engine is
operating under very hot conditions-or
when the car is driven off an expressway and
the hot engine is shut off. lnstead of
overflowing on the ground, the expanding
coolant is piped into the reserve tank to be
recycled into the radiator after the engine
cools down.
This system minimizes the necessity of
removing the radiator pressure cap to check
the coolant level. lnstead, the coolant can be
checked simply by observing the fluid level in
the reserve tank. The level should be
between the one- and two-quad mark on the
tank with the engine idling at normal
onoratinn tpmnpretr lrc
Spool-type engine mounts reduce
vibration, provide improved control.
An important development of Chrysler
engineering has been engine mount design.
Thls design area is a critical one-an area
that is of interest to the motoring public.
Chrysler believes that spool{ype engine
mounts are dependable. Spool{ype engine
mounts are used on all Chrysler passenger
cars.
Spool-type mounts provide control over
engine movements. Center bolts inside the
spool mounts limit engine movements that
could lead to radiator or other damage during
low-speed impacts.
All car engines tend to
"roll"
during
acceleration. The Chrysler mounts limit this
to a maximum roll of 3.0 degrees.
It is not likely that the rubber portion oI the
spool-type mount will fail. But should it do so,
the engine and frame will maintain direct
metal-to-metal contact.
Furthermore, Chrysler's flexible accelerator
cable reduces the effect of engine motion on
accelerator pedal feel, and reduces the
chance of mechanical bindino
More Chrysler engine features
Separator protector
New 325-ampere lightweight battery
20 amperes stronger, six pounds lighter and smaller in
size, this new lightweight battery provides faster
engine cranking lor the 318 V-8 engine than the battery
it replaces. ln addition, the new battery has the same
rugged case construction used with Chrysler's
500-ampere Long-Life Battery. The 325-ampere
battery is scheduled for 50% of 318 V-8 production by
January 1977 and full production by the end of the
model year.
Smaller, lighter,
stronger container
S00-ampere Long-Life battery
Heavy-duty construction throughout the
battery and a thermally insulated battery
shield (Thermo-Guard) account for the
reliability and long life of this battery. The
heavy-duty construction includes a durable,
three-piece polypropylene battery container,
heavier plates than those used in ordinary
batteries, rubber separators, and special
protectors for the separators. The
Thermo-Guard battery shield protects the
battery from engine compartment, so the
battery operates at cooler temperatures.
Cooler operation contributes to longer battery
life.
lmproved cell
connectors
Tests conducted by Chrysler engineers.
according to Society of Automotive
Engineers' battery test procedures with the
500-ampere Long-Life battery and the best
batteries of major competition-which
included original-equipment batteries of
Cadillac, Lincoln, Mercedes-Benz and
Rolls-Royce; and the best replacement
batteries of Sears (Diehard), Firestone
("Forever"), and J.C. Penney ("Maintenance
Free")-proved the following:
The 500-ampere battery has more
cold-cranking ability at its rated current
than any other battery tested.
The 500-ampere battery has more reserye
capacity than any other car battery tested.
The SOO-ampere battery has longer life
expectancy than any other car battery
tested.
The 500-ampere battery offers the only
s-year or 50,000-mile warranty among all
the original-equipment batteries tested.
What's more, Chrysler replaces the
500-ampere battery free of charge should
it prove defective during the warranty
period. Competitive original-equipment
batteries are replaced on a pro-rated,
partial credit basis.
.
See Chrysler Corporation Product
lnformation Bulletin 76-2, dated April 1976,
for actual test results as of that date.
100-ampere high-capacity alternator
This high-capacity alternator is included with the optional
electrically heated rear-window defroster on all Chryslers. The
100-ampere alternator has three special isolation mounts to
damp vibrations.
Higher amperage output was achieved by using more copper in
the windings than any previous Chrysler alternator. Finned,
nickel-plated copper heat sinks keep the diodes operating at
proper temperatures even while conducting more current.
A 65-ampere alternator is provided on full-size Chryslers wi''
the optional automatic temperature control air conditioning \
and with the optional trailer{owing packages; and on Cordoba
with the optional trailer-towing packages.
Amperage ratings for standard alternators are shown in the
standard and optional equipment lists in each of the car-line
sections of this book.
Thermo-Guard battery
shield
Chrysler's Thermo-Guard
battery shield can reduce
battery temperature rise up to
37% with the engine idling in
city traffic. This prolongs battery
life by protecting it from the high
engine-compartment
temperatures.
The Thermo-Guard battery :!
shield is made of tough
polypropylene plastic with
double-wall insulation forming
an inner and outer surface. An
opening in the shield permits
cooling air to circulate between
the battery and the shield.
Thermo-Guard is used with
all engines.
&L-
'*'{*M * @fu
-- q_e.&
1.
2.
3.
4.
New double-contact starter relay
This new starter relay has two contacts for
quicker and more reliable starting,
particularly in very cold weather. One
contact provides battery current to the
starter solenoid and to the starter motor for
cranking the engine-just as the previous
single contact starter relay did; while the
second contact provides current for a
circuit which bypasses the ballast resistor
and sends full-battery voltage to the
electronic ignition system coil so the high
voltage required to fire the spark plugs and
ignite the fuel-air mixture is available
instantly. The double-contact starter relay
is standard on all 1977 Chryslers.
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Cnrysler ignition wiring is
lnsulation
Glass and cofton braid
Jacket
tough and durable
Ordinary ignition wiring is subject to breakdown
caused by heat and chemical deterioration. The
high-tension ignition cable on Chrysler is strong
and exceptionally resistant to heat. The
conductor of the ignition cable is made of glass
filaments, uniformly treated with carbon. The
conductor is covered with a cotton and glass
basket-weave braid, covered by a thin layer of
conductive elastomer. The conductor is in-
sulated with EDPM rubber. A second layer of
cotton and glass braid surrounds the insulation
for stretch control and strength. A hypalon
rubber jacket is used on the outside to withstand
high operating temperatures, oil and ozone.
Silicone jackets with extra heat resistance are
used on the four rear spark-plug wires on 400
and 440 V-8 engines.
New ignition swatch has 50%
higher capacity
All 1977 Chrysler models, except those with tilt
or tilt-and-telescope steering columns, have a
new ignition switch with a 50"/" greater load-
carrying capacity than the switch used
previously.
The larger capacity results in reduced resistance
and improved electrical performance.
When the new ignition switch is in the
"accessory" position, the heater, defroster and
air conditioner are off; but the radio, gauges,
and wipers continue to operate.
New wiring harness terminal connectors
A newly designed wiring harness terminal
connector system replaces about 80% ol the
previously used blade terminal wiring
connections on all Chryslers. The new connector
system has a solid blade terminal with long
lead-in for better alignment and more positive
locking than the old system for reliable assembly
with the receptacle. This new connector also
provides superior electrical performance.
Circuits such as the ignition switch, taillights,
parking lights and many accessories have this
new-type connector.
More Chrysler engine features
Changes in exhaust
emission standards
lor 1977 are shown in
this comparison
chart:
To meet the 1977 emission control
standards, Chrysler engineers provide the
Cleaner Air System shown on this page.
Emission standards in grams per mile
Hydrocarbons
Carbon
Monoxide
Oxides ol
Nitro0en
1977 1976 1977 1S?6
'1s77
t976
All states
except California 1.5 1.5 15.0 1s.0 2.0 3.1
California 0.41 0.9 9.0 9.0 1.5 2.0
EXHAUST GAS RECIRCULATION
'EGR
Conlrol Valve
'EGR Vacuum Amplilier
'EGR
Time Delay
INTAKE MANIFOLD
'lmproved
Hot Spot
CARBURETOR
'
lmproved Distribution
'Leaner Mixture
'Faster
Acting Ghoke,
Electric Assisl
'External
ldle Mixture Limiter
'Solenoid
Throttle Stop
'
Gasoline Vapor Conlrol
'
ldle Enrichment
'Heat
Shield
DISTRIBUTOR
'Electronic
lgnition
'Beduced
Tolerances
'
Permanently Lubricated
PRESSURE.VACUUM
RELIEF FILLER CAP
COOLANT CONTROL
IDLE ENRICHMENT VALVE
CHARCOAL
CANISTER
ORIFICE SPARK ADVANCE
c0NTR0L VALVE (0SAC)
<::-
LEADED-FUEL RESTRICTOR
DOMED FUEL TANK
OXIDATION
CATALYTIC CONVEBTEB
CLOSED CRANKCASE VENTILATION
ROLL-OVER VALVE
VAPOR SEPARATOR
CCEGR
TEMPERATURE
VALVE
INCREASED
CAM OVERLAP
SPABK CONTROL COMPUTER
MINI OXIDATION CATALYST
(California
0nly)
FRESH.AIR INDUCTION
AIB PUMP
Air Swiiching
(Some Engines Will Use Aspirators)
HEATED INTAKE AIR
EXHAUST POBT AIR INJECTION
MODIFIED COMBUSTION CHAMBER
AND REDUCED COMPRESSION RATIO
Catalytic converter
controls emissions
The catalytic converter is basically a kind of
stainless-steel reactor in the car's exhaust
system that oxidizes hydrocarbons and
carbon monoxide to purify the exhaust
emissions. A noble metal catalyst in the
converter enables a heat-releasing reaction
to occur in the exhaust gases coming from the
engine. This reaction causes temperatures to
rise while oxidizing the hydrocarbons and
carbon monoxide so the exhaust emissions
meet Federal pollution standards.
Catalytic converter constructlon consists of a
stainless-steel shell with a ceramic honey-
comb monolithic element coated with a noble
metal catalytic agent. The monolithic element
is separated from the outside shell by a
stainless-steel mesh, which helps to insulate
heat and protect the honeycomb element by
providing a spring-type of shock absorbing
mounting. A flow diffuser at the entrance of
the conveder helps distribute exhaust gases
more uniformly throughout the ceramic
elements. Cars with catalytic converters must
use unleaded gasoline because elements in
leaded fuel coat the catalyst, rendering it
ineffective.
Sfarn/ess-stee/
shell
'Honeycomb
monolith-
coated with noble metal
Chrysler models for California (also
High-Altitude Packages) have an additional
converter-a mini-converter-and a power
heat control valve to reduce emissions of
hydrocarbons and carbon monoxide during
engine warm-ups. The mini-converter is
located adjacent to the left exhaust manifold
where it warms up quickly and begins its
catalytic action to reduce emissions. The
power heat control valve routes exhaust
gases from the right manifold through the left
intake manifold crossover to the exhaust
manifold so that all exhaust gases are subject
to the catalytic action. Once the engine
has begun to warm up, the main catalytic
convertertakes over and normal exhaust gas
flow is restored by the power heat control
valve.
H igh-altitude emission
control system
At high altitudes-4,000'above sea level and
higher-the air is less dense and contains
less oxygen per unit of volume. So, the
fuel-air mixture tends to run richer. This
causes an increase in exhaust emissions.
To compensate for this, engines sold in
localities above 4,000 feet are equipped with
the N96 Emission Control Package, which
includes high-altitude carburetor calibration
and spark-control modification.
Fuel pacer system
Chrysler's fuel pacer system (not available in
California or in high-altitude areas) is a
low-cost option that lets the driver know
immediately if he is pressing too hard on the
accelerator for economical driving. lt does
this by turning on the fender-mounted turn-
signal indicator light on the driver's side. The
driver can see this signal instantly without
taking his eyes off the road. To restore more
economical driving, he merely eases
off the accelerator until the signal light
goes out.
More about the fuel pacer system
When the ignition key is turned to start
the engine, the fuel pacer light will go
"on"-and
will go "out"
when the engine is
idling normally.
When driving under a heavy load-as when
pulling a trailer or climbing a steep grade-
the fuel pacer light may stay on for longer
periods because of engine requirements for
increased power and a richer fuel-air mixture.
The fuel pacer light will override the
fender-mounted, turn-signal indicator,
causing it to go from a flashing condition
to a steady
"on."
Fuel system improvements for
roll-over and collision protection
All 1977 Chryslers have improvements that
give extra protection against leakage to the
car's fuel system during side, rear and
angular front impacts. These improvements
include better fuel tank retention and stronger
fuel tanks, reinforcements in rear body
structural members and relocation of the
rollover valve, which prevents fuel leakage
during a full 360' rollover.
Staln/ess-stee/
Transmissions
Some facts about Chrysler's
TorqueFlite automatic transmission
The basic design of TorqueFlite includes three forward
gears, torque converter and precision automatic
shifting assembly. With TorqueFlite, no band
adjustments are recommended-and lhere are no
recommendations for changing the transmission fluid
and fluid filter.-
Chrysler, through the years, has been so convinced of
TorqueFlite's engineering superiority that it uses the
same basic design from the lowest priced compact car
to the highest priced Chrysler. Only the size of the
transmission varies in relation to the size of the engine
with which it is used.
Perhaps even more dramatic proof of Chrysler's
automatic transmission leadership lies in the actions of
other manufacturers.
For instance, one American auto maker uses a
transmission that is similar in design to TorqueFlite.
Two others have been buying Torqu-eFlite directly from
Chrysler Corporation for use in their own cars, trucks
and multi-purpose vehicles.
"Service is required if the car is used frequently for trailer
towing-or regularly operated under severe driving
conditions.
Low-slip torque converter
in TorqueFllte
The low-slip torque converter is
designed to stretch gasoline
mileage with TorqueFlite for both
city and suburban driving. This is
accomplished by reducing
torque-converter slip by uplo 22/o
on some models.
The illustration of the cutaway
torque converter shows how fluid
from the impeller (driving pump)
flows to the turbine (driven
member) back to the impeller by
way of the stator (stationary fluid
deflector). To reduce slip and
increase efficiency, the area of fluid
flow path (torus) has been
increased.
This reduces fluid flow friction
losses so that more energy is
available for turning the turbine
efficiently. Changing the angle of
the stator blades also changes the
torque multiplication and the
amount of slip. An increase in
engine torque also increases slip.
The low-slip torque conveder is
designed to achieve economy and
performance best suited for
today's conditions.
Other TorqueFlite data
o
Torque converter blades are brazed
for strength and efficiency.
o
Hydraulic cushioning devices are
used to soften the engagement into
reverse and low when the
transmission is put into gear.
o
Leak tests are performed on every
TorqueFlite transmission during
production.
o Liquid-cooled torque converter
provides cool, quiet operation and
added durability.
o
Clutch friction material does not
need to be replaced under normal
operating conditions.
o
Full-flow fluid f ilter does not need to
be replaced under normal operating
conditions.
r
Transmission fluid does not need to
be replaced under normal operating
conditions.
Console-mou nted TorqueFl ite
selector is available only with bucket
seats and console on Cordoba.
(Arrows indicate
fluid flow direction)
Rear axles
How axle ratios can
affect fuel economy
Changing rear axle ratios can affect gasoline
economy. The axle ratio determines the number
of times the engine will rotate the drive shaft
for each revolution of the rearwheels-provided
the transmission is in a 1 to 1 ratio high gear and
there is no torque converter slippage. lf the axle
ratio is 3.2 to 1, the engine will rotate 3.2 times
for every revolution of the rear wheels. lf the axle
ratio is reduced 1o2.7 to 1, it reduces the number
of drive shaft and engine revolutions to 2.7
for every turn of the rear wheels. Fewer engine
revolutions for each wheel turn tends to use less
gasoline-and that can translate into more miles
per gallon on the road. Other factors, such as car
size and weight, engine type and horsepower,
car speed and how the car is driven, tend to
vary the amount of gain in gasoline mileage that
is caused by using a lower rear-axle ratio.
Sure-Grip rear axle
This axle has an internal clutching device in
the differential that is designed to increase
torque to the non-slipping rear wheel, when
one wheel is on a slippery or loose surface.
When one rear wheel begins to slip, the
Power is channeled to wheel
with befter traction.
clutching device applies most oI the driving
torque to the wheel with the better traction.
This option helps keep the car moving on
surfaces where a car with an ordinary rear
axle would have difficulty.
97a" low'profile rear axle
This axle has a high load capacity and a large
offset drive pinion that permits using a low
floor tunnel. lt also uses straight roller wheel
bearings, is easy to service, and is designed
to reduce chances of lubricant leakage or
water entry. This low-profile axle is used on
many Chryslers.
Radial-ply tires can help to improve fuel economy!
Because radial-ply tires have less rolling resistance than bias-ply tires, they can improve fuel economy. Tests at the
Chrysler Corporation proving grounds showed that radial-ply tires can help to improve gasoline eponomy.
Chrysler offers 3 radial-ply tires for the 1977 Cordoba-
steel-belted, aramid-fiber-belted, and glass-belted!
Facts about tire sizes
A tire size designation, such as H7B x 15",
indicates three tire dimensions. The
prefix letter
"H"
is the tire's load rating and
relates to load-carrying capacity and the
cross-sectional size of the tire. The
"78"
indicates the ratio of the height of the
tire to the width of the tire; it means that the
height of the tire is about 78% of the tire width.
The
"15"
is the inside diameter of the tire and
also the size of the wheel on which it is
mounted. The radial-ply tires are identified by
the letter
"R"
in their size description. A
radial-ply tire would be HR78 x 15" as
compared with H78 x 15" for regular
construction tires.
No matter which radial-ply you choose for a
1977 Cordoba-steel-belted, aramid-fiber or
glass-belted-you get a tire with excellent
traction and roadability. That's because
radially constructed tires have flexible
sidewalls that allow them to flex indepen-
dently of the tread-so they don't lift the
tread from the road when the car is corner-
ing. This gives the car with radial-ply tires
more traction than a car with bias-ply tires.
Why 3 types of radial-ply tires?
Because each of the 3 types of radials is
designed to meet specific buyer needs.
Here's how they compare:
1) Steel-belted radials: long life
expectancy, great resistance to road
hazards, high initial price is justified
by
long service life.
2) Aramid-fiber-belted radials: aboul 21/z
pounds per tire lighter weight than
steel-belted radials, less low-speed
harshness, and belts as strong as steel.
3) Glass-belted radials: lightest weight of
the three (about 5 pounds per tire lighter
than steel-belted radials), reduced
low-speed harshness, less expensive;
however, they are not as strong and do not
have the wear potential of steel-belted
radials.
NOTE: See tire charts in Cordoba, Chrysler
and Town & Country sections of this
book for availability of tires.
O
78 series tire
O
70 series tire
Safety-Rim wheels have two special safety
ridges designed into the rim to help hold a
punctured tire on the wheel until the car can
be brought to a safe, controlled stop.
Safety-Rim wheels were first introduced by
Chrysler in 1941
,
and are now a required
safety feature on all cars.
------l_
Tire height
78o/o of 70o/o
tire width
rl
Radial-ply tires
Radial-ply tire Ordinary tire
Chrysler continues leadership . . . in
automotive electronics for 19771
Here is a short history of the electronic
advances that have kept Chrysler
Corporation in a leading position in
automotive electronics among U.S. auto
manufacturers.
1960-First made the alternator practical for
automotive use as standard
equipment by incorporating silicon
diodes as an electronic rectifier in the
design.
1970-lntroduced a modern silicon
electronic voltage regulator on all cars
and trucks. This device has no moving
parts and is much more reliable than
the electromechanical regulators
used previously.
1973-Made electronic ignition slandard on
all cars and trucks. This device
eliminated troublesome ignition
points and condenser-the major
causes of engine tune-ups.
1973-lntroduced the electronic digital clock
(chronometer) with quartz timing
crystal and digital readout. The
chronometer keeps time with much
greater accuracy than ordinary
electric clocks-and is much more
resistant to road shocks and
temperature extremes.
1976-lntroduced the electronic Lean-Burn
system featuring electronic spark
control. This system uses an
electronic computer and engine
and environmental sensors which
combine to adjust the timing of
spark-plug firings for best combustion
efficiency and engine performance.
1977-Expanded use of electronic Lean-
Burn system. Standard with the 440
4-barrel and 400 4-barrel V-B engines,
and available with some 360 4-barrel
V-8 engines. (See engine chart on
oaqe Vl for availabilities and
Electronic ignition solid-state components
are incorporated in the spark control computer of the
electronic Lean-Burn system!
Spark control computer is the brain
of the Lean-Burn system.
Don't expect to see the separate Electronic
lgnition control box under the hood when
you get an engine with the electronic
Lean-Burn system. That's because similar
solid-state components for the electronic
ignition are incorporated into the Spark
Control Computer for the Lean-Burn system.
Just remember that all Chrysler engines will
continue to have electronic ignition-with or
without the Lean-Burn system!
Electronic control
tor electronic ignition
Electronic components are
more dependable!
Chrysler Corporation is moving ahead
in electronics because the solid-state
components are more accurate and more
dependable than mechanical parts.
Electronic components have no moving
mechanical parts and no friction to cause
wear or malfunctions.
More about electronics
Condenser
Pick-up coil pole
piece
lgnition points
How electronic ignition changed the distributor
Oscilloscope shows superiority
of electronic ignition
The distributor used with electronic ignition has
no ignition points or condenser. A gear-like
reluctor (with a tooth for each spark plug)
rotates through the magnetic field of a
permanent magnet and produces a small
current in the distributor pickup coil. This
current, amplified by electronics, triggers the
high-voltage ignition coil. The electronic
control unit also helps to keep the high-voltage
available to fire the spark plugs at a
consistently high level. An air gap between the
rotating teeth of the reluctor and the permanent
magnet prevents contact and wear.
Rubbing block
A breaker-point-type distributor has a rubbing
block that rides up over the cam to open
and close ignition points for each spark plug
firing. As the rubbing block wears, the open
points move closer together and become pitted
and burned and timing changes.
Another problem with the breaker-point-type
distributor is that high-voltage energy available
to a spark plug is reduced as the contact
points wear and oxidize. After a time, one or
more becomes rough in operation. Eventually,
the engine cannot be started and the points
must be replaced.
Electronic ignition Former ignition system
after 55,026 miles after only 10,000 miles
The difference in available voltage for each
spark plug can be measured by an
oscilloscope comparison of electronic ignition
versus former ignition systems during starting.
The electronic ignition shown has run 55,026
miles; the former ignition system has run only
10,000 miles. The superior voltage
consistency of the electronic ignition system is
clearly visible. With distributor points and
condenser, an oscilloscope shows an
inconsistent voltage pattern in the ignition
system.
Reluctor
Electronic ignition has
these advantages
o
lgnition points and condenser are
eliminated from the distributor.
High-voltage energy is produced for the
spark plugs by highly reliable electronics.
Periodic timing and point adjustment are
not required with electronic ignition
because there are no points to wear or
burn. lgnition tune-up maintenance costs
are reduced.
Consistent high-voltage energy is
transmitted to the spark plugs to help
improve starling reliability and to help
improve highway performance. Up to 35%
more voltage is available to the spark plugs
during cold starting. With distributor points,
the voltage drops off during engine starting,
and voltage is less consistent at highway
speeds than with the electronic ignition
system.
Spark plugs should operate satisfactorily in
normal passenger-car service for 30,000
miles. The consistently high voltage of
electronic ignition greatly reduces the
incidence of mis-firing.
Alternator uses electronic
rectifiers to prolong battery life
ln 1960, Chrysler first made the alternator
practical for automotive use by incorporating
silicon diodes as an electronic rectifier in the
design. The alternator helps prolong battery
life by charging the battery even when the
engine is idling.
lntroduced in 1970, Chrysler's electronic
voltage regulator eliminated the need for
maintenance by eliminating moving parts.
Records show that 98% of the electronic
voltage regulators installed at the factory on
Chrysler models during the past 5 years
functioned properly with no replacement and
no problems during the warranty period. This
substantiates the claim of Chrysler
engineers that the electronic voltage
regulator is more reliable than previous
mechanical voltage regulators.
How electronic and electromechanical
voltage regulators difler
Chrysler's electronic voltage regulator
eliminates moving parts. Diodes, transistors
and space-age circuitry maintain the correct
voltage in the electrical system. And the
electronic circuitry is sealed in tough epoxy,
making it shock resistant, moisture resistant
and extremely durable.
Electromechanical voltage regulators have
moving contact points that open and close to
regulate the voltage in the electrical system.
The moving parts, plus the fragile
construction of the voltage regulator, can
cause trouble.
Chrysler's electronic digital clock has
received official chronometer certification by
the Swiss Observatory-internationally
recognized as the bureau of standards for
timekeeping. lt is accurate within one minute
per month.
The electronic circuitry is much more
resistant to temperature changes and road
vibrations than the mechanism in ordinary
car clocks-and the numerals can be read at
a glance. The electronic digital clock is
standard on New Yorker Brougham and is
available at extra cost on all other Chrysler
models.
Electronic voltage regulator Electromecnanicat voltage regulator
Electronic voltage regulator backed by seven years of maintenance-free service
-'W?-,w
More about electronics
r-*xt*-
I &'
{,,
Miniaturized solid-state radios are available on all 1977 Chrysler models. The compactness
of the solid-state circuitry permits a much smaller radio design without loss of clarity in
reception. The solid-state components in these radios are reliable and durable and are resistant
to road shocks.
Chrysler's solid-state radios can be played with the ignition switch in the
"accessory"
position
with very little drain on the battery.
Electronic differential amplifier for
automatic temperature control air conditioner
This is the solid-state electronic unit (or brain) that
controls the power servo of the automatic temperature
control system to achieve the interior car temperature
called for by the comfort control setting. Just set the
control lever at a desired comfort level and the electronic
control operates the system to obtain and maintain
that level.
Special sensors measure temperatures inside and
outside the car and send this information to the electronic
differential amplifiel so that adjustments necessary to
maintain the comfort setting can be made continuously.
The amplifier output determines servo mechanism
posltions that adjust fan speed, air-flow control doors, and
a blend-air temperature control door, permitting cooled air
to be reheated as required. The electronic unit controls
the entire system so that cooled air or heated air is
provided automatically to maintain the pre-set comfort
level regardless of changes in outside air temperature.
Electronic light-emitting diodes
make reliable warning lights
Light-emitting diode warning lights, to indicate
that fuel is low, engine coolant temperature is
high and electrical system voltage is low, are
standard on New Yorker Brougham, and are
available on Newport and Town & Country
models as part of the extra-cost Light Package.
A diode warning light for low fuel is standard on
Chrysler Cordoba.
These diodes glow to warn the driver when the
car's fuel level drops lo
l/e
of a tank or below,
and when electrical system voltage drops
below 11.2 volts. With this kind of advance
warning, the driver can drive to a service
station before the trouble gets out of hand. The
tiny diodes-much smaller than a regular
instrument-panel bulb-emit a bright red glow
when an electrical current passes through
them. Also, the diodes use only about 1/20th of
the electrical current required by a bulb. The
low-fuel diode is mounted just
to the left of
the "E" (empty) on the fuel gauge. The low-
voltage diode ls mounted just
to the left of the
"D"
(discharge) on the alternator gauge.
A small printed circuit board with solid-state
electronics is mounted behind each of the
gauges-fuel and alternator-and the light-
emitting diodes extend through openings
in the gauge faces. Since solid-state circuitry
is used with the diode, it is less subject to shock
damage than mechanical gauges. Light-
emitting diodes have a life expectancy many
times greater than ordinary instrument-panel
bulbs.
Light-emitting diodel
\
Printed circuit board
-Or'
More about electronics
Miniaturized solid-state radios are available on all 1977 Chrysler models. The compactness
oI the solid-state circuitry permits a much smaller radio design without loss of clarity in
reception. The solid-state components in these radios are reliable and durable and are resistant
to road shocks.
Chrysler's solid-state radios can be played with the ignition switch in the
"accessory"
position
with very little drain on the battery.
Light-emitting diodel
\
Printed circuit board
\
Electronic differential amplifier for
automatic temperature control air conditioner
This is the solid-state electronic unit (or brain) that
controls the power servo of the automatic temperature
control system to achieve the interior car temperature
called for by the comfort control setting. Just set the
control lever at a desired comfort level and the electronic
control operates the system to obtain and maintain
that level.
Special sensors measure temperatures inside and
outside the car and send this information to the electronic
differential amplifier, so that adjustments necessary to
maintain the comfort setting can be made continuously.
The amplifier output determines servo mechanism
positions that adjust fan speed, air-f low control doors, and
a blend-air temperature control door, permitting cooled air
to be reheated as required. The electronic unit controls
the entire system so that cooled air or heated air is
provided automatically to maintain the pre-set comfort
level regardless of changes in outside air temperature.
Electronic Iight-emitting diodes
make reliable warning lights
Light-emitting diode warning lights, to indicate
that fuel is low, engine coolant temperature is
high and electrical system voltage is low, are
standard on New Yorker Brougham, and are
available on Newport and Town & Country
models as part oI the extra-cost Light Package.
A diode warning light for low fuel is standard on
Chrysler Cordoba.
These diodes glow to warn the driver when the
car's fuel level drops to
t/e
of a tank or below,
and when electrical system voltage drops
below 11.2 volts. With this kind of advance
warning, the driver can drive to a service
station before the trouble gets out of hand. The
tiny diodes-much smaller than a regular
instrument-panel bulb-emit a bright red glow
when an electrical current passes through
them. Also, the diodes use only about 1/20th of
the electrical current required by a bulb. The
low-fuel diode is mounted just
to the left of
the "E" (empty) on the fuel gauge. The low-
voltage diode is mounted just
to the left oI the
"D"
(discharge) on the alternator gauge.
A small printed circuit board with solid-state
electronics is mounted behind each of the
gauges-fuel and alternator-and the light-
emltting diodes extend through openings
in the gauge faces. Since solid-state circuitry
is used with the diode, it is less subject to shock
damage than mechanical gauges. Light-
emitting diodes have a life expectancy many
times greater than ordinary instrument-panel
bulbs.
r
"$::::\
Chrysler Unibody steel structural
members are welded into Unibody.
Two-piece body-and -f rame construction used
by many compefitors. Separate frame is bolted
to underside of body.
Why Chrysler prefers Unibody
There are two ways to unite the frame and body
of a passenger car. The way used on many U.S. cars
is to bolt a separate full frame to the underside of a
car body.
The other way, used for many years on most Chrysler
cars, is to weld all body structural members and body
panels into a single unit-or Unibody..
ln Unibody, Chrysler builds the strength of the frame
into the body. The welded body members contribute
their combined strength to the strength of the total
vehicle.
.NOTE:
Chrysler tull-size models use a stub frame with
strong stee/ beams to support the powertrain and
fronf suspenslon components. Cordoba uses a
structural crossmember to support the power
train and front suspension components. Ihese
structures are bolted to the car-body structure
through thick rubber lso/ators.
.*
Unibody for Cordoba
Chrysler continues to utilize the benefits of
Unibody construction in all its car lines.
Cordoba, however, has a Unibody designed
to complement its advanced styling, while
incorporating many structural features to meet
front barrier impact standards. Some of these
features are:
.
Separate front wheelhouse construction.
o
Reinforced windshield pillars and front-door
hinge pillars.
.
Strong steel reinforcements are used inside
the body side sills extending rearward from
the front pillars.
Body construction
Chrysler Newport Unibody
Steel reinforcing extends forward from the
cowl area to the radiator yoke to absorb
impact loads.
Lower side rails at the sides of the engine
compartment are made of heavy-gauge
steel for extra strength.
Box-section members that join the forward
lower side rails with the body side sills are
made of heavy-gauge steel to withstand
high-impact loads.
I
Box-section members reinforce Unibody
Large box-section
windshield header and
pillar form a strong
support for the forward
roof area and a sturdy
frame for the windshield.
Front fenders have
box-section steel upper
reinforcements for
additional strength. The
fender assemblies are
also secured to body-side
sills.
lnner front
wheelhousings on all
Chryslers are one-piece
barriers designed to
protect the engine
compartment and outer
fenders from corrosive
road splash. They also
contribute to the
structural strength of the
car's front end.
Box-section roof side
rails give full-length
support to the car's steel
roof .
Rear roof pillar
construction on sedans
and hardtops begins at
the rear wheelhousing
and extends up into the
roof in one continuous
welded steel structure. ln
effect, the roof is welded
to a continuous steel arch
which spans the roof,
extends down the rear
roof pillars and is
anchored firmly in the
rear wheelhousings.
Body-side sills, made o{
heavy-gauge steel, have
box-section construction
for extra strength; the sills
are galvanized inside to
resist rust and corrosion.
Heavy-duty underbody
steel rails join
with the
steel floor to become
four-sided, box-section
members that suppod the
entire rear of the body
and are used for
attaching the rear
leaf-spring mounting
structures. For 1977,
these rails are reinforced
to withstand rear impact
requirements.
Chrysler Unibody steel structural
members are welded into Unibody.
Two-piece body-and-frame construction used
by many competitors. Separate frame is bolted
to underside of body.
Why Chrysler prefers Unibody
There are two ways to unite the frame and body
of a passenger car. The way used on many U.S. cars
is to bolt a separate full frame to the underside of a
car body.
The other way, used for many years on most Chrysler
cars, is to weld all body structural members and body
panels into a single unit-or Unibody.-
ln Unibody, Chrysler builds the strength of the frame
into the body. The welded body members contribute
their combined strength to the strength of the total
vehicle.
-NOTE:
Chrysler full-size models use a stub frame with
strong stee/ beams to support the powertrain and
front suspension components. Cordoba uses a
structural crossmember to support the power
train and front suspenslon components. These
structures are bolted to the car-body structure
through thick rubber r'so/ators.
Unibody for Cordoba
Chrysler continues to utilize the benefits of
Unibody construction in all its car lines.
Cordoba, however, has a Unibody designed
to complement its advanced styling, while
incorporating many structural features to meet
front barrier impact standards. Some of these
features are:
.
Separate front wheelhouse construction.
r
Reinforced windshield pillars and front-door
hinge pillars.
.
Strong steel reinforcements are used inside
the body side sills extending rearward from
the front pillars.
Body construction
Chrysler Newport Unibody
Steel reinforcing extends forward from the
cowl area to the radiator yoke to absorb
impact loads.
Lower side rails at the sides of the engine
compartment are made of heavy-gauge
steel for extra strength.
Box-section members that join
the forward
lower side rails with the body side sills are
made of heavy-gauge steel to withstand
high-impact loads.
4.,
Body anti-rust treatments-7-step dip-and-spray
Protection against corrosion and rust begins
with the bare sheet metal. Even before the
metal is formed into body panels, it is coated
to protect against rust. Galvanized steel is
used for body-side sills. When assembled,
each car body is thoroughly cleaned and
coated with special chemicals in Chrysler's
7-step, dip-and-spray process for maximum
protection against all forms of corrosion.
3. Second rinse dip
Unibody is again dipped
and sprayed for thorough
rinsing, then drained.
Lasting luster results from acrylic enamel
over epoxy primer. After the anti-rust
treatments, each Chrysler Unibody is
sprayed with 2 coats of tough epoxy primer.
Then it is oven-baked and sanded. Finally,
two coats of a new acrylic dispersion enamel
are applied and oven-baked to a glossy luster.
Acrylic enamel is buffable and highly resistant
to chipping, fading and corrosion.
The 7-step, dip-and-spray treatments
:
1. Cleaning dip
Unibody is dipped and
sprayed with cleaning
solution, then drained.
:
4. Phosphate dip
Unibody is dipped and
sprayed in ruslresisting
phosphate, then drained.
Autophoretic-the name for
Chrysler's new chemical
anti-corrosion process for some
chassis components
What is autophoretic? lt's a series of
metal cleaning sprays and baths;
followed by a series of cleaning rinses;
followed by a unique organic/inorganic
coating which is actually
self-depositing through an ionic
displacement process followed by a
reaction rinse which increases
corrosion resistance. There are two
oven bakings-the first at 2200F. metal
temperature for 5 to 10 minutes to dry
the coating; the second at 2750F. metal
temperature for a minimum of 5
minutes-to cure the coatings and give
them anti-rust and anti-corrosion
qualities.
Result: improved rust and corrosion
protection.
Which car parts get the autophoretic
treatments?
Stub frames and the front suspension
crossmember are protected by the
autophoretic anti-corrosion treatments.
ls the autophoretic process new?
Yes, Chrysler Corporation is the first
U.S. car manufacturer to use the
autophoretic coating process to protect
car parts against corrosion. lt replaces
an asphaltic-base paint coating used
previously.
5. Cold rinse
Unibody is dqqoed.ln{.
_
:
,i
2. First rinse dip
Unibody is dipped and
sprayed in warm water to
rinse off the cleaning
solution, dirt and
impu rities.
Body sound-deadening
for ride quietness
Molded headliner
Rear shelf pad
Door and window seals
Dash panel
r
Cowl Side Silencer
o
Plenum Silencer
o
Molded Dash Liner
'
o
Wiring Harness Seal
Door
o
PaneJ Deadener
CORDOBA INSULATTON AND SOUND.DEADENERS
Chrysler even uses an electronic approach to
engineering
"quiet"
into the ride of all its cars.
Experimental cars are driven on typical roads
while recordings are made of the internal
noise levels in the front and rear seats.
Subjective evaluations are made of the major
noise sources. These sources are then
Rear shelf sealers
Rear-roof pillar
o
Silencer Pads
r
Silencer Batts
Rear quarter panel
deadener
Low quarter barrier
treated with approprlate sound-reducing
components. Then, comparisons are made
with similar, untreated vehicles to determine
when an appropriate noise level
improvement is achieved. The result is what
Chrysler passengers expect from Chrysler.
Luggage compartment
o
Wheelhouse Silencers
o
Floor Mastic
r
Front Liner
Floor pan
r
Undercoating (Optional)
o
Jute Underlayment
Double Layer Mastic and Pad
Silencer
Fuel Tank Silencer Pad
Sound-deadening the car body
Chrysler engineers use a variety of acoustical
materials to reduce transmission of vibrations
and noises to the car's interior. Absorptive
blankets, jute pads and sound-deadening
mastic are applied to specific areas where
they are the most effective srlencers. Rubber
seals and sealers are used elsewhere.
Molded headliner
Door and window seals
Dash panel
o
Cowl Side Silencer
o
Plenum Silencer
r
Molded Dash Liner
o
Wiring Harness Seal
Lower quarter access
hole cover
Rear shelf pad and sealers
Under-shelf panel absorber
Hear roof pillar
o
Silencer Pads
o
Structural Baffling
and Sealing
Rear quarter panel
deadener
Luggage compartment
o
Front Liner
o
Wheelhouse Silencer
o
Mastic and Pad
Floor Silencer
Floor pan
o
Undercoating (Optional)
o
Jute Underlayment
o
Double Layer Mastic and
Pad Silencer
o
Fuel Tank Silencer Pad
Hood pads
(Optional)
Lower quarter trim pad
o
Panel Deadener
r
Silencer Pad
o
lnside Door Handle Seal
CHRYSLER INSULATION AND SOUND-DEADENERS
Torsion-bar suspension
Torsion-bar front springs and widely spaced multi-leaf springs are the main ingredients of Chrysler's
torsion-bar suspension. This suspension system is one of the important engineering differences
between Chrysler cars and their competition. Most competitive cars use coil springs, front and rear.
Lower control arm
Torsion bar
twlsts as wheel
rides over bump
How suspension design keeps Chrysler nearly Ievel during braking
Chrysler engineers raised the front pivot of the upper control arm higher
than the rear. This design causes the control arm to impart a lifting force to
the front of the car as the weight shifts forward during braking. The lifting
force resists brake dive to help keep the car nearly level when the brakes are
applied.
Torsion-bar suspension system controls brake dive, acceleration squat
Torsion-bar front suspension system is designed to resist front-end dip when you apply the
brakes.
Rear suspensions are designed to help reduce pitching and squatting when braking or
accelerating.
How the torsion bar works:
A torsion bar twists and untwists as the front
wheel rides up and down over bumps in the
road. Road shocks are absorbed by the
torsion bar before being transmitted to the car
body.
Front wheel
Upper control arm
Rearoivot
\
'*
'uu'\.',g:gr--
1. Torsion-bar front springs-
angled out at front on full-size
cars
2. Anti-sway bar-resists roll in
turns
3. Angled upper control
arms-resist brake dive
4. Pre-loaded, tension-type lower
balljoints on full-size and
intermediate cars
Diagonally mounted steel
struts-stabilize front-wheel
lower control arms
Widely spaced leaf springs at
rear-give wide-stance support
Shock absorbers
Rear axle mounted forward of
spring center to minimize
acceleration squat
Tension shackles on lull-size
cars
Torsion-bar suspension has a built-in car-height
adjustment-coil springs do not
Torsion bars can be adjusted easily to keep the front end of
the car at the proper height, regardless of the car's age or its
mileage. Turning an adjusting bolt raises the front of the car.
Widely spaced rear leaf springs provide
wide-stance body support and roll stability to the
rear of the car. Rear springs are mounted far apart
to support the body when it tends to roll in turns.
6.
7.
8.
More about suspension isolation
and
quiet
ride
Rubber isolators minimize
sound transmission
Chrysler uses rubber isolators to
reduce road noise and harshness
transmitted to the car interior. These
rubber isolators are installed at points
where suspension components mount
to the car's structure-points where
they can help absorb suspension
system vibrations.
Torsion-Quiet ride
ln full-size Chrysler models, rubber
isolators are used to isolate the entire
front stub-frame structure-which
supports the engine, transmission,
front suspension and steering-from
the car body. ln Cordoba, the front
suspension crossmember and torsion-
bar crossmember are isolated with
rubber. All models also use rubber
isolators where rear springs are
mounted to the rear axle and where the
rear springs attach to the Unibody.
The extra rubber provides quietness to
the ride-Torsion-Quiet Ride.
Rubber isolators
lor Chrysler
Eight rubber cushions
isolate the front stub-frame
from the car body. Numerous
rubber isolators cushion
individual suspension
components. Front-
suspension strut
mountings have
large rubber
bushings.
Rubber isolators for
Cordoba
Six rubber cushions isolate
the front crossmember and
torsion-bar crossmember
from the car body. Numerous
other isolators cushion
individual suspension
components.
Axle tube Axle spring clips
Oval snorkels
on carburetor air
cleaners reduce air
intake noises
smooths engtne
operation.
Powertrain sound dampers
Spool-type engine
mounts with bonded
rubber cushions
contribute to smooth
engine operation.
Power plant damper,
mounted at the rear of
the transmission,
absorbs powertrain
-- {t
\
s/
u\
.".;- \
a\
,:.')
\--/t,./',,
Y
Drive shaft vibration
absorber reduces
rear-end noises.
lso-clamp
Spring plate
Leaf spring
Rubber isolator
lso-clamp rear-spring-to-axle mounting
utilizes large rubber cushions between the
spring clamps and axle housing to reduce road
noises and axle vibrations before they can be
transferred to the leaf springs. lso-clamp mounts
are used on rear springs of all Chrysler models.
Oval rubber isolators lor
front mountings of rear leaf
springs are standard on all
models. These isolators
increase f ront-to-rear
cushioning. The extra rubber
in these isolators softens the
ride to accommodate
steel-belted, radial-ply tires.
A flexible rubber
coupling and a sliding
"pot" coupling in the
steering column of all
models help absorb
road shocks and
vibrations before thev
reach the steering
wheel.
Brakes
Front-wheel disc brakes
Disc brakes have good resistance to
"brake
fade." Brake fade is a condition which
leads to loss of braking effectiveness after
repeated
"panic"
stops. Front-wheel disc
brakes are standard on all Chryslers. A
high-ratio brake pedal is used on full-size
Chryslers to reduce effort required to stop the
car in the unlikely event the power booster
should fail.
Dual braking system gives
double safety. Every
\
Chrysler has separate
7
hydraulic systems for
front-wheel brakes and
rear-wheel brakes. The brake
system has a dual master
cylinder with two separate
hydraulic cylinders, pistons
and lines-one for the front
brakes, the other for the rear.
ln case of damage to one of
the systems, the other system
will continue to function
independently to bring the car
to a stop. A warning light
glows when the pressure is
low in either system.
Flared and finned rear brake
drums are used on Chrysler
full-size models. These flared and
finned brake drums provide better
cooling of the rear brakes than
drums without flaring or fins.
Rear brake system
Brake warning light
The parking brake on all Chryslers operates the
rear-wheel brakes and is actuated by a foot
pedal. The brake warning light glows to let the driver
know that the parking brake is engaged.
Chrysler's rear drum brakes are self-adjusting.
This means that the brakes adjust automatically
whenever the car is braked while backing up-as
when backing out of a driveway. Periodic brake
adjustments are not required.
Steering
Secfor-shaft
gear-clearance
adjusting screw
Steering
Recirculating-ball steering gear is used on all
Chrysler models. The recirculating-ball bearings
reduce friction when the steering wheel is turned.
Power steering is standard on all Chryslers. The
power unit substantially reduces driver steering
effort. With power steering, only 3.5 turns of the
steering wheel are required to move the front
wheels from full-left to full-right.
Safety
Safety features on all
1977 Chryslers built in
North America
o
Safety-Rim wheels
o
lmpact-absorbing bumper systems
o
Passenger restraint systems with
combination lap-shoulder belts Ior the
driver and right-front passenger, and lap
belts for all other passengers
o
Energy-absorbing steering column and
steering wheel
r
Dual braking system with separate
brake-fluid reservoirs in the master cylinder
for front and rear wheel brakes
o
Brake-fluid pressure loss warning light
(also functions when parking brake is
applied)
o
Hazard warning flasher system-flashes
all turn-signal lights even with the brake
lights on
r
Turn signals with lane-change feature
r
Backup lights
o
Padded instrument panel and sun visors
r
Front-seat head restraints
.
Energy-absorbing front seat-backs
o
lnside and outside rearview mirrors
.
Heater and defroster
o
Side marker lights and reflectors
r
Safety-action inside door handles
o
Seat-back latches on folding front seats
o
Electric windshield washers and wipers
r
Keyless door locking system
.
lgnition and steering-column lock
r
Break-in resistant trunk lock
e
Light system circuit breakers with
automatic reset
r
Wiring harness fusible links
o "Key-left-in-ignition"
buzzer
r
Doorgate ajar warning light
o
Nonoverride door locks (except driver's
door)
a
a
a
a
a
Resilient window crank knobs
Side door beams
Supplementary throttle return spring
Safety door latches
Safety inside door release handles
(non-protruding)
Fire-retardant interior materials
Rotary glove-box latch
Reinforced windshield header and roof
Glare reduction measures for windshield
wipers, instrument panel and steering
wheel
llorrhlc hall ioint rearview mirror morrnt
a
a
a
a
ENERGY.ABSORB!NG
STEERING COLUMN
S/otted
column
jacket
Mandrel
Weight reduction
How Chrysler is reducing car weight to
improve fuel economy
Car weight is a big factor in fuel consumption.
As car weight goes down, miles per gallon go
up. Cars of all sizes can improve fuel
economy by reducing weight. Chrysler is
engaged in a continuing program of weight
reduction for all its cars, primarily to improve
fuel economy. Here are some of the results:
CORDOBA
1) Lightweight, ultra-high-strength steel is
used for door beams and rear-spring
attaching brackets.
2) Thinner side window glass reduces weight
4.6 pounds. A change in the tempering
process gives the thinner glass strength
and safety equivalent to the thicker glass.
3) A lightweight polypropylene plastic air
shield is used between the hood and
radiator yoke.
CHRYSLER
1) Lightweight, ultra-high-strength steel is
used for door beams.
2) Thin glass is used for rear doors of 4-door
models and for fixed quarter windows of
pillared hardtops.
3) Sheefmetal gauge changes have
lightened the car about 10 pounds
After impact
Before impact
lnstrument panel
seruicing made easy
Speaker and defroster
outlet cover
pad
I nstrument panel assembly
Cluster housing
Upper cluster bezel
Chrysler believes that if and when you have to
make these minor replacements or
adjustments, the task should be made as
easy as possible. That's why Chrysler has
designed modular instrument panels for all
Chrysler models. These panels have easily
removable sections-such as cluster
bezels-and gauges, switches and controls
that can be removed from the face of the
instrument panel. Just remove the small
retaining screws and pop out the panel,
switch or gauge you want to service.
Specifically, the following units can be
removed from the face of the instrument
panel for servicing: radio, heater and
air-conditioning controls, switches for the
headlights, windshield wipers and washer,
electric rear-window defroster, and tailgate
window control on wagons, the electric clock
(except Cordoba) and all gauges. All gauges
mount into the cluster and are retained by
SCTEWS.
The instrument panel pad is molded over an
armature of fiberglass-reinforced polyester
plastic. This whole assembly is removable
from the panel face after removing the center
speaker grille on Cordoba. On full-size
Chryslers, the pad may be removed after
removing the instrument panel upper cover.
Some instrument bulbs on Cordoba are
accessible from behind the cluster without
removing any components; others can be
reached from the face of the panel after
removing only the cluster bezel, lens and
mask assembly. On full-size Chryslers, the
bulbs are reached by removing the cowl top
cover or the steering column cover and
reaching behind the cluster.
Modular instrument panels provide easy access
to fuses, switches, gauges and circuits
Swr?ches
Light bulbs do burn out, fuses are designed to
"blow
out" to protect overloaded electrical
circuits-so both must be replaced from time
to time. Other units, such as gauges and
switches, are not entirely foolproof and may
require occasional servicing.
How Chrysler has reduced
mai ntenance requirements
1. Electronics. Electronic ignition-no
ignition points or condenser to replace.
Electronic voltage regulator-no moving
parts to fail; maintenance free.
2. Spark plugs. Chrysler recommends
spark-plug changes every 30,000 miles with
unleaded gasoline.
3. Engine oil and filter. Chrysler
recommends changing engine oilevery 7,500
miles or 6 months, whichever occurs first in
normal service. Engine oil filter changes are
recommended at the lirst oil change and at
every other oil change thereafter.
4. Automatic transmission lluid and filter.
TorqueFlite automatic transmission has no
recommended fluid or lilter changes in
normal operation. Only in severe service, as
in trailer towing, is it necessary to change the
fluid and filter-and then, only every 24,000
miles.
5. Chassis lubrication. Down through the
years, Chrysler engineering has reduced the
number of required lubrication fittings in the
chassis. Now, only ball joints and steering
linkage have lube fittings-and they need to
be lubricated only at 30,000 miles or 3-year
intervals, whichever occurs first.
6. Long-Life battery. Chrysler's 500-ampere
Long-Life battery is standard with the 440 V-8
engine and the 400 V-8 on New Yorker
Brougham, and is optional with other
engines. The Operator's Manual
recommends that you check the water level
lust
once a year in normal service-unless a
malfunction of the charging system is
indicated.
7. Self-adjusting brakes. Chrysler's
rear-wheel drum brakes adjust themselves
automatically-and that has eliminated a
number of periodic service stops for brake
adjustments. Front-wheel brakes on all
Chryslers are disc brakes, which have a
reputation for long service life.
8. Steel-belted, radial-ply tires. The steel
belts make the tires tougher for greater
resistance to road hazards and longer life.
Steel-belted radial-ply tires are standard on
all full-size Chryslers.
9. More durable materials. Aluminized steel
or stainless-steel exhaust pipes and catalytic
converter and a stainless-steel radiator cap
have the ability to resist corrosion and last for
years. Aluminized steel tailpipes and
mufflers, galvanized body-side sills and 7-
step dip-and-spray body treatments are all
designed for long, trouble-free service. Many
other materials, components and testing
procedures-too numerous to mention
her+-are also employed in reducing
Chrysler maintenance.
4
Converting to the metric system
The metric system, once adopted, is
simple. lt's a system like our monetary
system, where everything is upgraded in
tens. ln our monetary system, ten pennies
equal one dime, ten dimes equal one
dollar, ten dollars equal a ten-dollar bill,
ten ten-dollar bills equal a hundred-dollar
bill, and so forlh.
Converting our present system of
measurements to the metric system and
vice versa, however, is not so simple.
Conversion ol engine displacements
ln our present measurement system, engine
displacement is stated in cubic inches. For
example: 3'lB-cubic-inch V-8. The metric system
uses liters for engine size; cubic centimeters (cm3)
for piston displacement.
The conversion results in numerous
fractions and decimals. So, the period of
transition-the period of becoming
acquainted with what the metric system
means in terms of our present
system-can cause some confusion and
will require exposure to both systems.
Once we become familiar with what the
metric measurements and quantities
represent in terms of our system, then the
use of the metric system is made easier.
To understand the conversion figures, jusl
remember:
1 liter
-
61.02 cubic inches, and
1 liter
-
1000 cubic centimeters (cm3)
Conversion of linear
measurements-wheelbase, overall
length-to metric
Linear measurements, such as wheelbase and
overall length of cars, are expressed in inches in
our system, but are stated in millimeters in the
metric system. Since one inch is equal to 25.4
millimeters, the metric numbers are much larger in
this conversion. Here are some examples:
-4-d0or
sedan i2-d0or specialty hardtop
..4-door
hardtop
Water boils at 212" Fahrenheit-
100" Celsius-at sea level
Perhaps, when you were in school, you were
familiarized with two temperature scales-
Fahrenheit and Centrigrade. Centigrade was
metric. The Fahrenheit scale was invented in 1709
by Gabriel Daniel Fahrenheit; the Centrigrade
scale was invented by Anders Celsius in 1742.
Today, the name Centigrade is being replaced by
the name Celsius in honor of Anders Celsius.
ln the Fahrenheit scale, water freezes at 32' and
boils at 212". ln the Celsius (Centigrade) scale,
water freezes at 0" and boils at 100'. (All readrngs
are for sea-level atmospheric pressure.)
With the adoption of the metric syslem, we must
become familiar with the Celsius scale and its
equivalents in our present Fahrenheit scale. Here's
how to convert from one to the other:
Fahrenheit to Celsius:
Fahrenheit temperature minus 32'times 5/9
For example: 212" 32"
-
180" x 5i9
-
100'Celsius
Celsius to Fahrenheit:
Celsius temperature times 9/5 plus 32'
For example: 100" x 9i5
-
180'+ 32'
-
212'Fahrenheit
318 cubic-inch V-8 =
360 cubic-inch V-8 =
4OO crrhic-inch V-8 :
5.2 liters
:
5.9 liters
:
6 6 litcrs
=
Cordobat
llow
Yoiler
Bouoham''
Chrysler
llewport'
Town &
Co[ntry
lilaoon
Wheelbase, inches .
Wheelbase,
millimeters......
1 15.0"
2921
124.0"
3150
124.0"
3150
124.0'
3150
overall length, inches
Overall length,
millimeters.......
215.3'
5469
231.0"
5867
226.6
5756
227.7"
5784
Some common measurements and their equivalents
1 pint :
.473 liter
1 quart :
.946 liter
1 gallon :
3.785 liters
1 liter
:
2.113 pints
1 liter
:
1.057 quarts
1 liter
= 0.264 gallon
1 cubic inch
:
.016 liter 1 liter
:
61.02 cubic inches
1 cubic centimeter
:
.001 liter
1 liter
:
1000 cubic centimeters
1 cubic inch
:
16.39 cubic centimeters
1 cubic centimeter
:
.0061 cubic inch
t horsepower
:
0.7457 kilowatt
1 Kilowatt
:
1.34'1 horsepower
1 inch
:
25.4 millimeters
1 inch
:
2.540 centimeters
1 inch
:
0.254 meters
1 millimeter
= 0.03937 inch
1 centimeter
:
.3937 inch
1 meter
:
39.37 inches
1 foot
:
304.8 millimeters
1 foot
:
30.48 centimeters
1 foot
:
0.3048 meter
1 millimeter
:
0.00328 foot
1 centimeter
:
0.0328 foot
1 meter
:
3.281 feet
1 yard :
91 .44 centimeters
1 yard
:
0.914 meters
1 centimeter
:
0.0109 yard
1 meter
:
1.094 yards
1 mile
:
1.609 kilometers
1 mile
:
1,609 meters
1 kilometer
:
.6214 mile
1 meter
:
.00062 mile
1 mile per hour
:
1.609 kilometers per hour
1 kilometer per hour
:
0.6214 mile per hour
displacement