Chevrolet has released new details about how they made the 2016 Malibu weigh nearly 300 lbs (136 kg) less than the current model.
First and foremost, the 2016 Malibu has an all-new body structure with high-strength steels which enabled the use of thinner components in certain areas. This helped to save approximately 120 lbs (54 kg) of weight while also improving the car's ride and handling characteristics.
The model also uses more aluminum than its predecessor. Notable highlights include aluminum suspension knuckles and an aluminum hood that is 6.6 lbs (3 kg) lighter than the current model’s steel hood.
Inside, the 2016 Malibu has new power window regulators that save 4.2 lbs (1.9 kg) and a simplified instrument panel which saves an additional 2.2 lbs (1 kg). Even the center console has been optimized with a one-piece structural shell that enables it to weigh 1.75 lbs (0.8 kg) less than the one on the current model.
Other saving include new leather seats that are 40.6 lbs (18.4 kg) lighter and an all-new 1.5-liter turbo engine that weighs 86 lbs (39 kg) less than the previous 2.5-liter unit.