2016 Malibu – Larger, Lighter, Stronger and Safer

GMs first truly competitive mid-size offering in decades is coming at us with an approximate 300-lb weight reduction.

Wayne Gerdes – CleanMPG – June 21, 2015

2016 Malibu Hybrid – Pricing TBA while offering a 48/45/47 mpgUS city/highway/combined rating. Just 3,100 pounds for the non-hybrid.

The 2016 Chevrolet Malibu midsize sedans quest to be more fuel efficient, stronger and safer. As in nearly 300 pounds lighter than the current model that improves efficiency, ride and handling.

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 – 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-and-handling 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.

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 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 – a 34-percent reduction over the current model, while another 2.2 pounds 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 lighter than the current model.

4. Lighter leather seats and other soft materials - The Malibu’s available leather seats are collectively 40.6 pounds lighter than the current model. Additionally, about 1.5 pounds was saved with new trunk liner material and another 1.1 pounds 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 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.

2016 Chevrolet Malibu


It is pretty nice looking too!

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 offering a segment-best estimated efficiency of 48 mpg city, 45 mpg highway and 47 mpg combined.

2016 Malibu – Larger, Lighter, Stronger and Safer