- Despite being 120 pounds lighter, the new body structure is better in a crash and significantly stiffer than the outgoing Malibu. Chevy credits improved design and significantly higher percentage use of high strength steel.
- The new base engine, a 1.6-liter turbo, is 86 pounds lighter than the outgoing base engine, the 2.5-liter four.
- An amazing 40 pounds were removed form the car by using lighter, but more durable, leather and other materials such as the trunk liner.
- More aluminum is the industry trend, and the Malibu gets a new aluminum hood that reduces mass above the center of gravity. Also, the suspension is more aluminum-intensive which reduces unsprung weight. Both changes improve handling.
- Seven pounds were cut when Chevy redesigned the window hardware and instrument panel.
Dropping 300 pounds is amazing for a car that will weigh about 3,200 pounds. As vehicles drop in weight, the effect can snowball as brakes and other components no longer need to be as heavy since they will be doing less work.
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