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2016 Chevy Malibu exhaustively tested with four decades of data

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. 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.

Fernando Alonso sputters in his Indy test

INDIANAPOLIS — Helio Castroneves and Fernando Alonso kept waiting around Wednesday. Now both international stars have some unfinished business to take care before qualifying for this year's Indianapolis 500. After enduring a rain delay of more than four hours then watching IndyCar regulars turn laps at Indianapolis Motor Speedway for two more hours, Castroneves and Alonso finally made it onto the track — but couldn't quite complete their refresher course. "Happy to be back here because this place is great," Alonso said after posting a fast lap of 218.690 mph — the slowest of the nine-driver evening session. "We were slow because the weather and some of the decisions people made on running time and things like that." He faced a bevy of problems in his first trip back to Indy since an impressive rookie performance in 2017. The rain delay forced organizers into rescheduling the one-day test, moving the rookie and refresher driver time from midday to the evening, cutting a significant amount of practice time for Alonso and the others. And when the green flag finally waved, Alonso's No. 66 car stalled in the warmup lane forcing the two-time Formula One champion from Spain to be towed back to pit lane where his crew worked feverishly to fix an electrical problem while sat in the cockpit. Eventually, he did get out and passed the first of two refresher phases. He'll have to wait until opening practice of the 500 on May 14 to pass the second. "It was frustrating for everyone because it was a brand new chassis and a brand new car, so we expected to run a lot," said Alonso, who drives for McLaren Racing. "If we could have had this at midday, you could work on your issues in the afternoon and then go out again." To put his day in perspective, Takuma Sato, the 2017 Indy winner from Japan, posted the fastest lap of the day at 226.993 mph and Colton Herta was the fastest rookie at 226.108. Castroneves, as usual, was good right from the start and posted a fast lap of 225.565. The three-time Indianapolis 500 winner looked smooth and fast on his favorite track and wasted no time passing the first phase. That much should have been expected from the popular Brazilian, who has recorded seven top-three finishes in 18 Indy starts and will make his season debut May 11 in the IndyCar Grand Prix. The weather and yellow flags prevented four of the five veterans — Castroneves, Alonso, Oriol Servia and JR Hildebrand — from passing phase two. Only Indy native Conor Daly made it.

Chevy's 6.6-liter Duramax is pretty much all new

To say there's a heated battle in heavy-duty pickups is an understatement, with Chevrolet, Ford, and Ram constantly trading blows of increased torque, horsepower, and towing capacity. The latest salvo is the revised, more powerful turbo diesel 6.6-liter Duramax V8 in the 2017 Chevy Silverado. It has 910 pound-feet of torque, an increase of 145, putting it nearly level with the Ford Super Duty. Here's a closer look at where those gains come from. How exactly did Chevrolet add all that torque plus 48 horsepower? The automaker essentially took a fine-tooth comb to the entire engine. Chevy says it changed 90 percent of the V8, and the cumulative effect of those small changes adds up to big increases. As you might guess, the turbocharger is updated. The larger unit features electric actuation of the variable nozzle turbine (VNT), and what Chevy calls a double axle cartridge mechanism that separates the VNT moving parts from the housing. That helps with heat performance as well, with a claim that the exhaust side of the turbo can run continuously up to 1,436 degrees Fahrenheit. Helping that cause are six exhaust gaskets made of Inconel - an nickel alloy that contains chromium and iron – and upgraded stainless steel for the exhaust manifold. Despite having the same cast iron cylinder block, albeit with some minor enhancements, the engine has new cylinder heads, pistons, piston pins, connecting rods, and crankshaft, which have all been upgraded to handle 20 percent higher cylinder pressures. Alongside the increase in pressure, Chevrolet also increased the cylinder head's structure with a honeycomb design. The pattern features high-strength aluminum with dual layer water jackets that not only improve strength, but also optimize water flow for better cooling. For 2017, the cylinder head also benefits from integrated plenum that aids the engine in getting more air under heavy loads. The cylinder head isn't the only component to get a minor update, as the pistons have a larger diameter pin for improved oil flow. The same detailed improvements has been bestowed to the humble connecting rods (second in our hearts only to the inanimate carbon rod). The new design has the bolts oriented roughly 45-degrees to the rod instead of parallel. The angle split design, as it's called allows for easier passage through the cylinder.