Editors: CORRECTS 7th paragraph to remove extraneous words; CORRECTS
magnesium to manganese in Fast Fact
For Release: Wednesday, June 17, 2015, 8 a.m. EDT
5 Ways Chevrolet Made 2016 Malibu Segment’s Lightest
Approximately 300-lb weight reduction enhances efficiency, driving dynamics
DETROIT – Engineers developing the 2016 Chevrolet Malibu put the new midsize
sedan on a strength-training program, making it sweat out a pound here and a
gram there, in a quest to make it more fuel efficient, stronger and safer.
The result is an all-new Malibu that is nearly 300 pounds (136 kg) lighter than the
current model – an achievement that not only gives it the segment’s lightest base
curb weight, but also contributes to an estimated 48 mpg in city driving for the
hybrid model and 37 mpg highway for the 1.5L turbo base engine. A lighter curb
weight will also improve ride and handling.
“Imagine you’ve got a 300-pound lineman riding on the roof of your car and he
decides to jump off – you’re going to notice a change in performance immediately,”
said Jesse Ortega, chief engineer. “That’s what we’ve done with the 2016 Malibu,
with the mass savings spread throughout the vehicle, providing greater overall
balance, a more responsive and agile driving experience and lower fuel
consumption.
“The Malibu team was challenged to look for weight savings in every area of the
vehicle, no matter how small, because every gram adds up,” said Ortega. “The aim
was to make Malibu the most mass-efficient car in its class.”
Here are five of the most noteworthy mass-saving achievements:
1. Leaner, stronger body structure
More than a third of the 2016 Malibu’s mass savings – approximately 120 pounds
(54 kg) – comes from its all-new body structure, which features greater use of
high-strength steels, enabling the use of thinner components in some areas, while
delivering comparable or better crash performance.
The stronger-yet-lighter structure is also stiffer than the current model, which
allowed suspension components to be tuned more precisely. Engineers had less
body flex for which to account, contributing to the new Malibu’s sharper ride-andhandling reflexes.
Development of the Malibu’s structure is the result of extensive computational
analysis, which employed sophisticated modeling programs to simulate dozens of
design iterations that indicated the most strategic placement for high-strength steel
elements such as the pillars and rockers – all while maintaining higher targets for
strength, stiffness and crashworthiness.
“The analysis took the guesswork out of the Malibu’s development, allowing the
chassis to be developed with the just-right level of structural components,” said
Amir Sewani, structural engineer. “After the structure was determined, we started
looking at all the components that are attached to it, evaluating where they could
be optimized for lower weight.”
2. Greater use of aluminum
Light and strong, the incorporation of more aluminum in the 2016 Malibu
contributes significantly to its lower weight. Examples include an aluminum hood
that is 5.6 pounds (2.5 kg) lighter than current model’s aluminum hood, and
aluminum suspension knuckles and chassis components, as well as lighter mounts.
An additional benefit of the aluminum suspension components is reduced un-sprung
mass, which contributes to the Malibu’s responsiveness.
3. Streamlined instrument panel assembly and lighter power accessories
New power window regulators collectively save 4.2 pounds (1.9 kg) – a 34-percent
reduction over the current model, while another 2.2 pounds (1 kg) was saved by
reducing the complexity of components within the instrument panel. That included
simplified construction with more integrated parts – and fewer components in the
assembly.
Even the center console has a streamlined, one-piece structural shell that is 1.75
pounds (0.8 kg) lighter than the current model.
4. Lighter leather seats and other soft materials
The Malibu’s available leather seats are collectively 40.6 pounds (18.4 kg) lighter
than the current model. Additionally, about 1.5 pounds (0.7 kg) was saved with
new trunk liner material and another 1.1 pounds (0.5 kg) was shaved with new,
proprietary interior carpet material that also is more durable than the current
model.
5. A lighter engine
The 2016 Malibu’s all-new, standard 1.5L turbo engine is 86 pounds (39 kg) lighter
than the current model’s standard 2.5L engine, while delivering comparable
performance. Its lighter weight also enhances the Malibu’s front-to-rear weight
balance – another contributor of the car’s more responsive driving experience.
The 2016 Malibu goes on sale in the fourth quarter of 2015. It will be offered in L,
LS, LT and Premier trims, as well as a Hybrid model, which leverages Chevrolet Volt
technology to offer segment-best estimated efficiency of 48 mpg city, 45 mpg
highway and 47 mpg combined.
Curb Weights Compared
2016 Chevrolet Malibu 1LT (1.5L Turbo)
2015 Ford Fusion SE (2.5L)
2015 Toyota Camry LE (2.5L)
2015 Hyundai Sonata SE (2.4L)
2015 Honda Accord LX (2.4L)
2015 Nissan Altima SV (2.5L)
2015 Kia Optima EX (2.4L)
CURB WEIGHT
3,100 lbs (est.)
3,461 lbs
3,240 lbs
3,252 lbs
3,192 lbs (man. trans.)
3,206 lbs
3,272 lbs
EPA HIGHWAY FUEL ECONOMY
37 mpg (GM est.)
34 mpg
35 mpg
37 mpg
34 mpg (man. trans.)
38 mpg
34 mpg
FAST FACT: High-strength steel alloys typically contain manganese to
enhance strength.
Founded in 1911 in Detroit, Chevrolet is now one of the world's largest car brands, doing
business in more than 115 countries and selling around 4.8 million cars and trucks a year.
Chevrolet provides customers with fuel-efficient vehicles that feature engaging
performance, design that makes the heart beat, passive and active safety features and
easy-to-use technology, all at a value. More information on Chevrolet models can be found
at www.chevrolet.com.
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CONTACT:
Chad Lyons
Chevrolet Communications
313-670-2045
chad.lyons@gm.com