Malibu Diet Saves 300 lbs

General Motors Co.'s 2016 Chevrolet Malibu midsize sedan weighs just 3,100 lbs, making it the lightest vehicle in the segment, according to the company. It's 92 lbs lighter than the Honda Accord and 106 lbs lighter than the Nissan Altima.

The all-new Malibu is nearly 300 lbs lighter than the current model. It has an EPA rating of 37 mpg with the base 1.5-liter four-cylinder engine better or equal to all its midsize competitors except the Altima (38 mpg), GM says.

More than one third of the Malibu's mass savings (120 pounds) is derived from its body structure. The all-new architecture makes greater use of high-strength steels, enabling thinner components in some areas, while maintaining or improving crash performance.

GM employed advanced computational analysis to simulate dozens of design iterations and optimize material placement.

The lighter structure also is stiffer than that of the current model. GM says this allowed it to more precisely tune suspension components to improve ride and handling characteristics.

The new Malibu has more aluminum, including the hood, suspension knuckles, mounts and chassis components. The hood is 6.6 lbs lighter than the steel unit it replaces.

Other weight savings come from:

• switching to a 1.5-liter engine from the current 2.5-liter unit (86 lbs)
• using leather seats (40.6 lbs)
• redesigning the power window regulators (4.2 lbs)
• reducing instrument panel complexity (2.2 lbs)
• streamlining the center console (1.75 lbs)
• developing a new trunk liner (1.5 lbs)

GM will introduce the 2016 Malibu this autumn. It also is planning a plug-in hybrid variant that is expected to get a segment-best 47 mpg.