Chevy is preparing to unveil its new Malibu sedan at the upcoming New York Auto Show next month. But when it does, it's not like it will have appeared overnight.

The development of any new vehicle – especially one as widely produced by a major automaker as the Malibu – involves rigorous and relentlessly punishing tests. In the Malibu's case, that meant 1.5 million miles of driving from the scorching heat of Arizona in July to the frigid cold of northern Canada in January and everything in between.

The Bowtie brand also says it incorporated four decades' worth of data taken from vehicles driving in locations around the world since 1972 in order to make the Malibu the best it could be. We'll have to wait to find out the results of all that exhaustive testing, but you can catch a sneak peek at the new sedan in the video above.

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Four Decades of Data Used to Test 2016 Chevrolet Malibu
Recorded customer use drives durability testing for next-generation midsize sedan

2015-03-11

DETROIT – Data collected over decades from across the globe is helping ensure the 2016 Chevrolet Malibu can handle the world's worst roads even if the all-new midsize sedan never drives on them.

Data collection boxes are placed in cars in real-world driving conditions around the world. Since 1972, these devices have accurately recorded the harshness and frequency of every jounce, bump and shudder inflicted on the car on roads in the U.S., Russia, Saudi Arabia and developing markets.

"Although most Malibu owners will never put their car through similar abuse, we test all new vehicles in extreme climates, inclement weather and on punishing road surfaces," said Dan Devine, Malibu validation engineer. "The 2016 Malibu is definitely up to these challenges."

Tests like these ensured the current generation Malibu was dependable and durable, two qualities that in turn helped Malibu stand out from its rivals in important quality surveys, such as J.D. Power's Initial Quality Study and Vehicle Dependability Study.

General Motors engineers analyze the data to calculate the precise amount of damage potholes and other hazards create over 150,000 miles. Then the conditions are replicated at GM's Milford Proving Ground in Michigan on three unique road courses, each riddled with simulated potholes of increasing severity. Engineers run preproduction cars through the course up to hundreds of times.

Additional validation and development tests include logging more than 1.5 million miles of driving in controlled environments and on open roads.

The 2016 Malibu also endured some harsh weather through drives in scorching Yuma, Ariz. – which averages 107 degree temperatures in July – and sub-zero cold of Northern Canada – which averages a low of -13 degrees in January. At the GM Technical Center in Warren, Mich., the Malibu put in several hours in the Climatic Wind Tunnel, where temperatures can be raised to 140 degrees or lowered to 40 degrees below zero.

The new Malibu also endures a battery of stationary and dynamic tests to simulate abuse well beyond the average lifetime of the car. These tests include:

- A four-post vehicle test which balances each wheel on a hydraulic post that actuates the suspension at high frequency, accelerating the wear on bushings and dampers.
- Door, hood and decklid slams speed up wear on hinges and latches.
- Road durability testing includes extremes such as twist ditches, driveway angles, mud and gravel, high-speed tests, chatter bumps, Belgian blocks and salt spray.

The 2016 Chevrolet Malibu will be available late in 2015.

About Chevrolet
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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