Northern Tennessee got more than a taste of German Fest when Volkswagen, Europe's largest automaker, opened its first U.S. assembly plant from scratch in the sprawling fields and hills surrounding picturesque Chattanooga; it experienced an economic rebirth.
The state-of-the-art facility, opening for duty in 2011, represents a $1 billion investment to the region. Ground breaking and construction began in 2009.
Currently, the front-wheel-drive Passat is the sole product built at the plant; as time marches forward, more product will be added. Still, with just one model, the plant remains active 20 hours a day six days a week. Helping to power the plant are 33,600 solar panels producing 12 percent of the facility's energy needs during full production and 100 percent during non-production times. It's the largest solar park in Tennessee.
Volkswagen's mid-size Passat sedan, built exclusively for the North American market, received a next-generation makeover in the 2012 model year (coinciding with the Chattanooga plant opening). In 2012, Volkswagen's U.S. sales topped 438,000 units, an impressive 35 percent jump from 2011.
Three Passat engine selections are available, including our tester's high-mileage and exceedingly intriguing 2.0-liter, four-cylinder turbo-charged diesel. European automakers have tweaked diesel (at times referred to as combustion power engines) powertrains for more than a century. Currently 50 percent of passenger vehicles sold in Europe utilize diesel powertrains; by contrast, U.S. sales account for less than four percent.
That small U.S. percentage continues inching upward. In 2012, U.S. clean diesel sales increased 21 percent from the previous year. All three U.S. domestic automakers have new clean diesel models debuting in the next two years. One reason: better fuel economy. Our mid-sized Passat with turbo direct-injection (TDI) diesel listed mileage at 31 mpg city and 43 mpg highway teamed with a six-speed manual transmission. Passat TDI earns the top spot as the most fuel efficient mid-size 2013 sedan sold in America not incorporating pricier gas-electric hybrid or pure-electric plug-in technologies. While diesel's extra engine weight and insulation add a price premium, it's less than hybrids or plug-ins.
Today's ultra-low sulfur clean diesel fuels meet the same quality standards as conventional unleaded gas and is readily available throughout Chicagoland. Stale-egg fumes and sooty emission exhausts prominent decades ago are all but a foggy memory thanks in part to a nitrous oxide catalyst and filters, acting as scrubbers to filter out small particulates before exiting the exhaust chamber . With higher mandated fuel economy standards looming, diesel is ready-now technology (with fuel-delivery infrastructure in place) improving fuel economy more than 20 percent over a similar-sized gasoline engine. Diesel fuel's high-energy density and slower burn properties add up to enhanced mileage.
Rather than spark plugs, diesel engines utilize highly compressed air to ignite cylinder activity (sometimes with the aid of warming glow plugs). In addition to better fuel economy, enhanced low-end torque improves low-speed dynamics such as accelerating from a standing start. Mid-range passing power on the highway also improves.
Rounding out Passat's troika of engines are two gas-powered offerings: a 2.5-liter five-cylinder generating 170 horses and 3.6-liter six cylinder cranking out 280 horses.
The five-cylinder gas model is available in four trims: S, SE, SEL and SEL Premium. The clean diesel offers two: SE and SEL Premium while the six-cylinder offers and SE with a sunroof and SEL Premium. All trims offer dual climate control; power windows, locks, doors, and power-motion driver seat.
Our 2013 TDI SE trim with six-speed manual checked in at $26,225. No option packages on board brought the bottom line to $27,020 with $795 destination charge. When debuting last year, this fourth-generation effort promoted a lower starting price than the outgoing Gen 3 to more effectively compete in the heated mid-size sedan segment. A base S five cylinder gas model with six-speed manual checks in at $20,845, not the segment's lowest, but now more competitive. With six-speed automatic, the list price is $22,945. Passat prices escalate quickly when stepping up the trim ladder.
Volkswagen and its up level Audi division have both historically designed comfortable interiors interfacing well with drivers and occupants. The single-sectioned glove box is good sized while another dashboard bin folds down left of the steering column below the headlight dial. Front buckets combine the best of two worlds; supportive without too much harshness and extra thigh support. Back fatigue remained totally absent during a two hour trip west to the Mississippi River (with great gas-mileage results, but more about that later).
The three-toned dashboard formed a "T" design with the center stalk region morphing down to the floor-mounted transmission shifter. A black top side gets accented with a horizontal brush aluminum strip below and white under accents which continue onto the seats. Interspersed along the top are four rectangular air vents; the center two flanking an analog clock. The lower portion of the 'T" includes three smallish-yet-convenient dials monitoring ventilation functions. Below is a small storage area with spring-loaded door front for stowing valuables like portable electronics. Rearward of side-by-side beverage holders is a deep, narrow storage bin home to iPod connections in all trims above base S.
The instrument panel includes two circular gauges with small circular inserts at the bottom of each; the fuel gauge residing inside the right-side speedometer housing. A square digital window toggles through a myriad of informational nuggets via a scroll on the three-spoke steering wheel. Cruise control functions are found on the turn-signal stalks end tip.
The six-speed manual transmission includes a convenient hill holder clutch, preventing Passat from rolling backward for a couple of seconds when the clutch pedal is disengaged and the accelerator pressed.
Passat qualifies as a true five seater thanks to oodles of leg and decent head room in row two. Pull-tab-like lock mechanisms unlatching the 60/40 split rear seat backs are found in the average-sized trunk. Under the flat-floored cargo region is a welcome spare tire, albeit a temporary variety. Drivers experience good visibility thanks to a large rear and decent-sized side windows.
The fuel tank provides a relatively large 18.5 gallon capacity. While our TDI tester required diesel fuel, the naturally aspirated five cylinder utilizes regular 87-octane unleaded while V6 models recommend premium 91 octane fuel.
During a mid-winter getaway from DuPage County west to the Quad Cities straddling the mighty Mississippi River, fuel economy actually surpassed the 43 miles per gallon highway estimate by a couple miles even with some city travel thrown in for good measure.
A handsome, flowing exterior exemplifies curvy corners rather than sharp edges. It's simple, clean and anything but radical. The front end consists of an iconic, circular VW logo inside three long horizontal grille bars. Thin headlight housing stretches to the front fenders while strap-like door handles share body color. Secondary blinker bands adorn side-view mirrors.
The higher-compression engine design makes a bit more noise at idle, but it's no deal breaker. At the pump, diesel's fuel's pungent odor is evident. Getting even a drop or two on shoes will keep the smell lingering for a while.
For those looking to maximize fuel economy and performance, diesel is no longer a dirty word.
2013 Volkswagen Passat TDI
Price as tested: $27,020
Engine: 2.0-liter turbo direct injection four-cylinder diesel
Horsepower: 140
Fuel estimates: 31 mpg city, 43 mpg highway
Length: 191.6 inches
Wheelbase: 110.4 inches
Height: 58.5 inches
Width: 72.2 inches
Curb weight: 3,393 pounds
Drivetrain warranty: five-year 60,000 miles
Assembly: Chattanooga, Tennessee