Day two started with a detour on the back roads of Kentucky, where the Passat proved that arrow-straight directional stability is not its only dynamic forte. It may take a while to adjust your inputs to the light effort and prompt action of the car's controls, but once you've accustomed yourself to the proper driving style, the reward is a neat handling balance, a pleasant fluidity of motion, and enough feedback to enjoy the drive. At no time did this Passat feel like a cheap car -- which is just as well, because it isn't. Priced at $28,665 with the dual-clutch automatic but without add-ons, the Passat TDI is not inexpensive. But when you consider the exceptional fuel economy (in heavily policed terrain, the test car returned an impressive 40 mpg), the comprehensive warranty, and the three years of free maintenance, it is pretty reasonable. The latest U.S.-built VW is a lot more grown-up and complete than the first U.S.-built VW, the rudimentary Rabbit that was handicapped by skinny thirteen-inch wheels, low-grade materials, and the bargain-basement aesthetic that was pervasive in economy cars of the era. On the plus side, Volkswagen advertised that the car returned up to 56 mpg on the highway in knock-out-your-ears diesel form, and it was even available as an extended-wheelbase trucklet for farmers with miniature cattle and accordingly slim budgets. Although the Rabbit never aspired to be more than a bargain-basement Beetle replacement, the new Passat qualifies as a downsized, low-cost Phaeton.
After some 1.1 million U.S.-hatched Volkswagens, the final curtain fell in 1988, when the company drifted into a sales and identity crisis that not even the New Beetle with its cute dashboard vase could terminate. Twenty-three years later, the Germans are back with a new assembly plant in what not long ago was the world's biggest new-car market. Having received $100 million in government aid for the $350 million Westmoreland project, VW can this time count on an estimated $575 million contribution to its $1 billion Chattanooga enterprise. Only six months after the Pennsylvania plant opened, workers went on strike in an eventually successful bid to reportedly increase pay from $7 to $12 an hour. The wage scale in the not-yet-unionized Tennessee factory ranges from $14.50 to $19.50 per hour. On top of that, there is health care, available low-cost car leases, a pension plan, and various bonus programs. Thanks to a much higher degree of automation, more modern assembly processes, and a growing number of parts from Mexico (five-cylinder engines), Poland (TDI), and Germany (V-6), the brand-new greenfield site needs barely 2000 workers to build 150,000 vehicles per year in two shifts. And that is only the beginning.
Westmoreland -- which was originally built as a Chrysler plant -- and its habitat are as different from the gleaming Chattanooga monument as the proud-to-be-basic 1970s Rabbit is from the slick new Passat. New Stanton was Boomtown America for exactly one decade, an unassuming point on the map of Pennsylvania that grew and shrank in a single ill-fated cycle. In contrast, the Tennessee facility is embedded in a more robust social and demographic environment. What unites the two locations is Volkswagen's quest to build a car that is 100 percent right for North America. The Rabbit was, in essence, the right answer to the first energy crisis, but it didn't take long before fuel again became less expensive and more plentiful and buyers began opting for bigger and more comfortable cars. And that is exactly what they are getting from Chattanooga, where the $20,695 Passat is rolling off the line at nearly full steam. "Everything is on track to reach the targeted 460 units per day by the end of 2011," says Andreas Linke, head of quality assurance at the Tennessee plant.
The new volkswagen drive is again a proud two-lane highway laid out like its almost forgotten counterpart some 600 miles to the northeast. In grand sweeps, it leads to and circles a complex that is so big you can glimpse it in its entirety only from an elevated vantage point. But whereas the old factory was a compromised layout inherited from another carmaker, the new home is state-of-the-art. The acreage is clearly sufficient to double or even triple capacity. "Today, we can produce 150,000 cars a year," Linke states. "Adding a third shift and streamlining operations would increase the output to 250,000 units. Midterm, it would only take a moderate investment to erect a duplicate plant and double production to half a million vehicles." VW doesn't say what other models it might build in North America, but in addition to the aforementioned Passat wagon, the Wolfsburg grapevine has repeatedly suggested a seven-seat crossover based on the Passat's component set. Eventually, VW will probably also bring in the more advanced and more flexible MQB architecture pioneered by the next-generation Golf. Although local content is soon expected to reach 85 percent, it is worth mentioning that all stampings are currently sourced from outside suppliers. To keep complexity at a minimum, assembly is based on simple "one touch, one motion" steps. "It sounds extremely basic," the director admits with a smile, "but so far, this approach has yielded a strong rating on the internal quality scale -- which means that our model is on par with the Passat made in Germany."
In Westmoreland, employee relations were strained and the product suffered in the wake of frantic cosmetic changes, compromised assembly methods, and recurrent labor unrest. The Rabbit was neither a Golf nor a substitute for the Beetle. It was a stopgap model that was designed to take on tough times and tough competitors, but it faltered because the company forgot to include traditional brand values like durability, longevity, street cred, and Fahrvergnuegen. The new Passat has all that and more. Although it is sufficiently German in design, character, and execution to please American tastes, it is sized right and priced right to suit American needs. Add to this a significant fuel economy advantage, and you have a formula that is likely to work much better in 2012 than it did in 1978. The one thing the new Passat needs is more emotion. It is definitely neither a soul-stirring handling champ nor a king of the fast lane nor a g-force conquistador. But being able to let 750 miles elapse between pit stops does have a certain charm of its own in these difficult times, and in terms of value for money, square inches per pound of steel, and equipment for dollar, the new mid-size sedan from the Volunteer State has probably got all it takes to become America's next favorite Volkswagen.
2012 VOLKSWAGEN PASSAT TDI
BASE PRICE: $28,665
ENGINE: 16-valve DOHC turbo-diesel I-4
DISPLACEMENT: 2.0 liters (120 cu in)
HORSEPOWER: 140 hp @ 4000 rpm
TORQUE: 236 lb-ft @ 1750 rpm
TRANSMISSION: 6-speed dual-clutch automatic
L x W x H: 191.6 x 72.2 x 58.5 in
WHEELBASE: 110.4 in
TRACK F/R: 62.1/61.0 in
WEIGHT: 3459 lb
EPA MILEAGE: 30/40 mpg