Service Training

Self-study Programme 425

EcoFuel Natural Gas Drive

with 1.4 l 110 kW TSI Engine
Design and Function
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 After the successful application of the EcoFuel natural gas drive in the Touran and Caddy, this technology is now also
being used in the Passat, Passat Estate and Touran – for the first time in conjunction with a TSI twincharger engine.

From an environmental viewpoint, increased use of this technology is worthwhile because the emission of harmful
exhaust gases are reduced considerably compared with petrol operation, for example, carbon dioxide (CO2)
by 25 %.

The Passat TSI EcoFuel with 7-speed dual clutch gearbox therefore produces just 119 g/km of CO2 in natural
gas mode.
Furthermore, the exhaust gases produced in natural gas mode do not contain sulphur, soot or fine dust.
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S425_002

On the following pages, we will introduce you to the design and function of the natural gas drive in the
Passat TSI EcoFuel.

You will find further information on the topic of natural gas in self-study programme no. 262 “Natural gas – an
alternative fuel for motor vehicles” and no. 373 “EcoFuel Natural Gas Drive in Touran und Caddy”.

The self-study programme portrays the
design and function of new developments!
The contents will not be updated.
For current testing, adjustment and repair
instructions, refer to the relevant service literature.
Important
Note

2
 Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
The Passat TSI EcoFuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
The 1.4 l 110 kW TSI twincharger engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Engine Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Changes to engine components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Natural Gas Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

The Passat TSI EcoFuel natural gas drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Engine Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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System overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Actuators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Electronic gas pressure regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Functional diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Special features of natural gas vehicles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Test Yourself . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

3
 Introduction

The Passat TSI EcoFuel

The Passat TSI EcoFuel uses a dual drive. That means it can be driven in both natural gas and petrol mode.
In addition to the components for petrol operation, further components for natural gas operation are required.
You can see these in the illustration below.
You will find more detailed explanations of these components in later sections of this self-study programme.

General vehicle data

- Capacity of natural gas tank 21 kg natural gas * Natural gas H (high) has a higher methane
- In natural gas operation, consumption content than natural gas L (low). The higher
of 4.4 kg natural gas H* every 100 km and the methane content, the better the natural
a range of approx. 480 km gas quality and the greater the range.
- Capacity of petrol tank 31 l petrol
- In petrol operation, the consumption is 6.8 l petrol
every 100 km and the range approx. 460 km
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Electronic gas pressure regulator with

high-pressure valve for gas mode N372
and Tank pressure sensor G400

S425_002

S425_063 S425_055
Gas fuel rail with gas injection Gas shut-off
valves 1 - 4 N366 - N369 and valve relay
gas rail sensor G401 J908

4
 Gas filler neck with non-return valve
(an adapter is required for Italy)

Natural gas tanks with tank shut-off valves 1 - 3 N361 - N363

(tank shut-off valve 3 N363 with non-return valve)

S425_017

S425_043
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S425_004

Petrol tank

S425_041

S425_028
Dash panel insert with
natural gas gauge G411, fuel gauge G1,
natural gas mode warning lamp K192 and
reserve fuel warning lamp K105

5
 Introduction

The 1.4 l 110 kW TSI twincharger engine

This engine has already been used in different vehicle
models. However, due to the thermal and mechanical
loads in natural gas operation, several components
in the engine have been modified. The natural gas
functions have been added to the engine management.

Technical features

● One engine control unit for natural gas and petrol

operation
● Homogenous mode (Lambda 1) in both operating
modes
● Turbocharger with waste gate S425_005
● Selectable mechanical supercharger
● Gas fuel rail with gas rail sensor and gas injection
The torque/output graph is identical in
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valves
both operating modes. To achieve this,
the supercharger is activated for longer in
natural gas mode than in petrol
operation. Furthermore the boost
pressure is approx. 0.3 bar higher.

Technical data

Engine code CDGA

Type 4-cylinder in-line engine

Torque and output diagram
Displacement 1390 cm3

Bore 76.5 mm

Stroke 75.6 mm

Valves per cylinder 4

Compression ratio 10:1

Torque (Nm)

Output (kW)

Maximum output 110 kW at 5500 rpm

Maximum torque 220 Nm at

1500 to 4500 rpm

Engine management Bosch Motronic MED 17.1

Fuel Natural gas H (high)

Natural gas L (low) with
reduced range
Super unleaded RON 95

Exhaust gas treatment Main catalytic converter,

Lambda control
Engine speed (rpm)
Emissions standard EU5
S425_006

6
 Engine Components

Changes to engine components

As a fuel, natural gas has a higher anti-knock index compared with petrol in addition to its clean combustion.
The octane number for natural gas H can be up to RON 130. This allows an earlier ignition time without combustion
knock. The efficiency increases whilst the combustion pressure and combustion temperature in the combustion
chamber also increase. However, natural gas is very dry and does not have any lubricating properties like petrol.
All of this leads to increased loading on the engine and requires changes to the engine components.

Pistons, piston rings, piston pins,

connecting rods
Piston
The forged pistons are hard anodised in the first and
second piston ring grooves. To reduce the surface
pressure in the piston hub, the piston pin has been Piston rings
made slightly longer.
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The top piston ring has a high wear-resistant coating.

Piston pin
The upper small end bearing and the small end bush S425_008
Connecting rod
are made from a more wear resistant material.

Valve timing of camshafts

Inlet camshaft
The closing segment of the inlet and exhaust cams
has been made less severe. As a result, the valves are
closed slightly more slowly and the mechanical load
is reduced. Exhaust camshaft

Closing
S425_011
segment

Valves, valve stem seals, valve guides

Valve stem seal
The inlet and exhaust valves are nitrated and
reinforced. The valve guides are made from highly Valve guide
wear-resistant material. The valve stem seals have a
second sealing lip that forces lubrication of the valve Valve
Valve seat
stem in the valve guides. A material with greater wear
and corrosion resistance has been chosen for the S425_012
valve seat rings in the cylinder head.

7
 Engine Components

High-pressure injectors 1 – 4 N30 - N33

In petrol operation, the high-pressure injectors are Aluminium

cooled by the fuel (petrol) that flows through them. heat sink
There is no cooling in natural gas mode. Since these
valves protrude directly into the combustion chamber,
S425_030
unacceptable high temperatures would result.

Two measures have therefore been taken:

Teflon ring with high
thermal conductivity
- a second Teflon ring with a high thermal
conductivity and
- a heat sink made from aluminium to transfer the
heat from the high-pressure injector to the cylinder
head.
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Oil pump, coolant pump, coolant Thermostat 1

distributor housing Thermostat 2

The delivery rates of the oil and coolant pumps have

been increased – the oil pump has a higher drive
speed and the diameter of the coolant pump impeller
has been increased from 54 to 60 mm.
Coolant
distributor housing
To keep the temperature in the cylinder block down,
thermostat 2 in the coolant distributor housing opens
at 80 °C. Duo-centric
oil pump

Coolant pump

S425_064

Oil spray nozzles, oil cooler

Oil spray nozzle
Due to the high combustion chamber temperatures in
natural gas mode, the piston crowns are heated up
Oil cooler
greatly. The oil spray nozzles are designed for a
higher oil delivery to keep the temperatures as low as S425_013
possible.

Two cooling plates have been added to the oil cooler

to increase the cooling performance.
Cooling plates
S425_032

8
 Turbocharger

To obtain a faster turbocharger response, the Turbocharger

compressor wheel has been made slightly smaller.

S425_014

Spark plugs

Conventional spark plugs would soon wear out due

to the greater ignition requirement and the higher
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spark temperature in natural gas operation. Therefore S425_031

Centre electrode
the materials used in the spark plugs have been made from
changed. The centre electrode is made from a 0.6 mm iridium
iridium pin and the earth electrode is made from
platinum. Earth electrode made
from platinum

Exhaust system

The exhaust system only stretches to the front natural

gas tank. This allows the natural gas tanks and the Three-way catalytic
converter
petrol tank to be made as large as possible.

To fulfil EU5, the thickness and composition of the

coating in the three-way catalytic converter has been
modified for natural gas operation. This is necessary
S425_015
as highly temperature-resistant methane is left after
incomplete combustion.

9
 Natural Gas Drive

The Passat TSI EcoFuel natural gas drive

In the Passat TSI, natural gas mode is mainly used. This means that the driver does not have the option of switching
back and forth between the operating modes. If all conditions for natural gas operation are met, the engine will
always start and run in natural gas mode.

Gas filler neck with filter and non-return valve

The gas filler neck is behind the tank filler flap on the right-
hand side of the vehicle above the petrol filler neck. There is
a non-return valve and a metal filter on the gas filler neck.
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Gas filler neck with filter

and non-return valve Natural gas tanks 1, 2, 3
with a capacity of 21 kg

Mounting bracket

Tank shut-off valves 1 and 2

N361, N362

Protective covers

Tank shut-off valve 3 N363

Connecting piece with

double clamping device
High-pressure
High-pressure natural gas line and connecting pieces natural gas line

The natural gas line is made from stainless steel.

To ensure that the gas pipes cannot leak, the individual
sections are connected with double-clamping devices.

10
 Note that the pressure must be released
in the natural gas high-pressure pipe
before you carry out work on the natural
gas system. Please note the instructions
in ELSA.
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Please note that even if the system has
been switched over from natural gas to
petrol operation because the gas supply
has been exhausted, there will still be a
residual amount in the natural gas tanks.

Gas fuel rail with

gas rail sensor G401 and
gas injection valves N366 - N369 Electronic gas pressure regulator with
fuel tank pressure sensor G400 and
high-pressure valve for gas mode N372

Connections for
coolant circuit

S425_016
Low-pressure
natural gas line

11
 Engine management system

System overview
Sensors
Intake manifold pressure sender G71 with
intake air temperature sender G42

Intake manifold pressure sender 3 G583 with

intake air temperature sender 3 G520

Charge air pressure sender G31 with

intake air temperature sender 2 G299

Engine speed sender G28

Electronic power control
fault lamp K132

Hall sender G40

Exhaust emissions
Throttle valve module J338 warning lamp K83
Throttle valve drive angle sender 1 - 2 for
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electric throttle G187 - G188

Regulating flap control unit J808

Control unit in
Regulating flap potentiometer G584
dash panel
insert J285
Accelerator position sender G79 and
accelerator position sender 2 G185

Clutch position sender G476

Brake pedal position sender G100

warning lamp K192
Natural gas mode
gauge G411

Fuel gauge G1

Reserve fuel warning

Natural gas

Fuel pressure sender G247 lamp K105

Knock sensor 1 G61

Coolant temperature sender G62

Radiator outlet coolant temperature sender G83 Tank pressure

sensor G400

Lambda probe G39

Gas rail
Lambda probe after catalytic converter G130 sensor G401

Brake servo pressure sensor G294

Components
Additional signals for natural gas mode

12
 Actuators

Engine control unit J623 Fuel pump control unit J538

with ambient Fuel system pressurisation pump G6
pressure sender

Injectors for cylinders 1 - 4 N30 - N33

Ignition coils 1 - 4 with output stage

N70, N127, N291, N292

Inlet camshaft
control valve 1 N205
Powertrain CAN

Turbocharger air recirculation valve N249

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Charge pressure control

Onboard
solenoid valve N75
supply control unit J519
Data bus diagnostic
interface J533 Throttle valve module J338
Throttle valve drive for electric throttle G186

Regulating flap control unit J808

Regulating flap position control motor V380

Motronic current supply relay J271

Diagnostic
connection Fuel pressure regulating valve N276

Activated charcoal filter solenoid valve 1 N80

Magnetic clutch for supercharger N421

High-pressure valve
Lambda probe heater Z19
for gas mode N372

Gas injection
valves 1 - 4 Lambda probe 1 heater after catalytic converter Z29
N366 - N369

Gas shut-off valve Additional coolant pump relay J496

relay J908 Coolant circulation pump V50
Tank shut-off valve 1 - 3
N361 - N363
Additional output signals

S425_023
13
 Engine Management

Engine control unit J623

The engine control unit is installed in the centre of the plenum chamber. It manages all functions of petrol and
natural gas operation. Lambda = 1 is used in both operating modes.

In basic settings, you switch manually in

display group 243 to natural gas mode
and in display group 244 to petrol mode.
This may be helpful when you are
searching for faults.

S425_049

Cold start function

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If the vehicle is started at a coolant temperature below 10 °C, a cold start function for the gas injection valves is
activated in petrol mode. This involves adding natural gas (measured at 15 % of the total quantity of fuel required)
to the petrol while the high-pressure valve for gas mode is closed.
Once the natural gas from the gas fuel rail has been burnt, the gas injection valves are fully powered for approx.
60 seconds. As a result, the temperature in the valves is raised by approx. 35 °C and the gas injection valves will
not become clogged. Next the high-pressure valve for gas mode is activated and the pressure is built up again in
the gas fuel rail. The system then switches over to natural gas mode as soon as possible.

Emergency start strategy

If it is not possible to start the engine in one operating mode within 4 to 8 seconds (depending on the coolant
temperature), it will be started in the other operating mode.

This means, for example:

- If the coolant temperature is 20 °C and no natural gas has been filled up, the vehicle will start in natural gas
mode. If this is not possible because of a fault in the natural gas system, it will start in petrol mode.

- If the coolant temperature is 0 °C, the vehicle will start in petrol mode. If this is not possible because of a fault in
the petrol system, it will start in natural gas mode.

On-board diagnose II

The on-board diagnosis checks all components and systems relevant to the exhaust gas while the vehicle is running.
It stores the malfunctions and indicates exhaust gas-related errors with the exhaust emissions warning lamp K83.

14
 Starting strategy

The table shows the starting strategy of the 1.4 l 110 kW TSI EcoFuel engine.

Coolant temperature** < 10 °C Coolant temperature** > 10 °C

Start in petrol mode

No
prior Switch over to natural gas mode Start in
natural gas Cold start function completed, natural gas mode
fill-up* coolant temperature > 10 °C and
time after start > 100 seconds

Start in petrol mode Start in petrol mode

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Until natural gas quality

With adjustment has been completed
prior
natural gas
fill-up* Switch over to natural gas mode Switch over to natural gas mode
after activating the Lambda control, after activating Lambda control, but
cold start function completed, after 540 seconds at the latest
coolant temperature > 10 °C and
time after start > 100 seconds

* Natural gas refuelling

Natural gas engines have very good lean-running capabilities, but relatively poor rich-running capabilities. If
natural gas H (rich) is injected with the same opening time as natural gas L (lean), there could be problems when
the engine is started and performance could be poor. To avoid this, natural gas mode cannot be used until the
Lambda control is activated and the natural gas quality can be recognised.

If the engine control unit is informed by the fuel tank pressure sensor G400 that the pressure in the natural gas
tanks has increased 30 % since the engine was last run, it will presume that the tank has been filled with natural
gas. A natural gas quality adjustment is carried out by the Lambda control and the opening times of the gas
injection valves are adjusted. The adjustment is carried out in the middle load/rev range and lasts 60 seconds. The
adjustment is interrupted outside the range and the time counter is stopped. The engine will start immediately in
natural gas mode only once the adjustment has been completed.

** Coolant temperature

At coolant temperatures above 10 °C, the coolant is definitely warm enough to prevent icing of the gas pressure
regulator while the natural gas pressure is regulated.
Furthermore the valve seats of the gas injection valves are sealed by elastomer seals. At very low temperatures,
they can clog and no longer open. That no longer occurs from 10 °C.

15
 Engine Management

Sensors
Fuel tank pressure sensor G400 High-pressure gas inlet
from the natural gas tanks
Tank
The fuel tank pressure sensor is screwed into the pressure sensor G400
electronic gas pressure regulator.
It is connected to the high-pressure area via a
transverse passage and measures the natural gas
high pressure.

Signal use

S425_062
This signal allows the engine control unit to recognise

- the filling level of the natural gas tanks,

- whether natural gas has been filled up and Effects of signal failure
- whether the tank shut-off valves are leak-free. The
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valves are closed for up to 4 seconds once per
driving cycle in a range close to idle for this
purpose. The residual gas from the natural gas
pipes is burnt and the pressure should fall. If it
does not fall, at least one of the valves is leaking.
If the signal fails, the natural gas gauge shows full.
The vehicle continues to drive in natural gas mode,
but will start in petrol mode next time as if the vehicle
has been refuelled. If Lambda control is active, the
system switches to natural gas mode.

Gas rail sensor G401

Gas rail sensor G401

The gas rail sensor G401 is bolted onto the front side
of the gas fuel rail. It determines the natural gas
pressure on the low pressure side.

Signal use

The signal is required by the engine control unit

- to determine whether the natural gas pressure is

S425_061
sufficient for natural gas mode,
- to regulate the natural gas pressure in the gas fuel
rail at 5 - 9 bar and
Effects of signal failure
- to calculate the opening times of the gas injection
valves.
If the gas rail sensor signal fails, the system switches
immediately to petrol mode.

16
 Actuators
Tank shut-off valves 1 - 3
N361 - N363
Tank shut-off valve
Each natural gas tank has a tank shut-off valve.
They seal the natural gas tanks when the ignition
is set to “OFF”.

Task S425_018

The valves are closed when not powered and prevent

gas flowing out of the natural gas tanks.
In natural gas mode, the solenoid valves are activated Effects upon failure
together via the gas shut-off valve relay J908 and
open the path to the electronic gas pressure regulator. If one of the valves fails, the vehicle continues to drive
They are opened by the filling pressure while the in natural gas mode while there is sufficient natural
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vehicle is filled up. gas.

If a leaking valve is recognised via the fuel tank
pressure sensor G400, a fault memory entry is made
and the exhaust emissions warning lamp K83 is
switched on.

Gas injection valves N366 - N369

The gas injection valves are inserted into the cylinder

intake ducts. They are activated by the engine control
unit in natural gas mode.

Task
S425_021
They have the task of feeding natural gas into the
intake manifold.
Gas injection valve
The opening times of the gas injection valves depend
on:

- the engine speed,

- the engine load,
- the natural gas quality and S425_054
- the natural gas pressure in the gas fuel rail.

Effects upon failure

If one of the gas injection valves fails, the system

switches over to petrol mode.

17
 Engine Management

Electronic gas pressure regulator

The electronic gas pressure regulator is mounted on
the longitudinal member at the front right of the
engine compartment.

It regulates the pressure in the low-pressure natural

gas system at 5 - 9 bar (absolute). In the previous
Touran/Caddy EcoFuel models, it was reduced
mechanically to a fixed value of approx. 7 bar
(absolute).

S425_025
Electronic gas pressure
regulator
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The electronic gas pressure regulator is made up of

the following components:

Fuel tank pressure sensor G400 High-pressure gas inlet

from the natural gas tanks
This sensor is connected to the high-pressure area via
a transverse passage and measures the natural gas Coolant
Low-pressure gas outlet
high pressure. connections
to engine

1st and 2nd reduction stage Tank

pressure sensor G400
The first reduction stage reduces the natural gas
pressure to 20 bar and the second to 5 - 9 bar.

Mechanical excess pressure valve

This valve is screwed into the low-pressure area of the

gas pressure regulator and opens at approx. 16 bar. S425_047
This prevents natural gas flowing into the low-pressure
area at a high pressure and causing damage.
Mechanical
2nd reduction stage
Coolant connections high-pressure valve for
pressure relief
valve opens at
gas mode N372 approx. 16 bar
When the natural gas pressure is reduced, a large 1st reduction stage

amount of heat is drawn from the surrounding Breather hole for

components. This creates very low temperatures that pressure relief valve
can lead to icing. To avoid this, the gas pressure
regulator is incorporated into the coolant system and
heated by the coolant.

18
 Regulation of natural gas pressure

Regulating the natural gas pressure at 5 - 9 bar (absolute) allows the following advantages in the Touran/
Caddy EcoFuel models compared with a fixed pressure of 7 bar (absolute):

Gas is injected at a pressure of 5 bar up to the middle
load/rev range. The low pressure allows the vehicle to
drive for longer in natural gas mode. This increases
the range by up to 25 km.
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Gas is injected at a pressure of 9 bar in the upper
load/rev range. This allows more gas to be injected
per working cycle at the maximum opening time of
the gas injection valves. This is the only way that an
output of 110 kW or a torque of 220 Nm is possible.

Electronic
gas pressure regulator
System pressure (bar)

max. gas mass flow at

full load 35 kg/h

Mechanical
gas pressure regulator
max. gas mass flow at
full load approx. 27 kg/h

Gas mass flow (kg/h)

S425_053

Switch-over between operating modes

To ensure that sufficient natural gas continues to flow into the low-pressure natural gas system, the pressure in the
high-pressure natural gas system needs to be higher than the pressure at which it is injected. It needs to be at least
6 bar in the lower load/rev range and at least 15 - 17 bar in the upper load/rev range. If the pressure is lower, it will
not be possible to deliver the natural gas as quickly as it is injected and combusted by the engine.

If the natural gas pressure falls below these pressure thresholds in the respective ranges, the system will switch to
petrol mode. In the upper load/rev range, the driver can now take his foot off the accelerator and carry on driving
in the lower load/rev range. Once the natural gas pressure reaches a sufficient level again (at least 6 bar), the
engine control unit switches back to natural gas mode. This switch-back can be carried out twice. If the pressure
falls below the threshold again, the car will drive further in petrol mode.

19
 Engine Management

1st reduction stage

Reduction of natural gas pressure to approx. 20 bar

The gas pressure is reduced in two stages in the gas pressure regulator. The pressure in the first reduction stage is
reduced mechanically to approx. 20 bar.

High-pressure gas inlet In-flow of natural gas

The natural gas pressure is less than 20 bar behind

the hollow piston.
Hollow piston

The natural gas flows from the natural gas tanks into
the electronic gas pressure regulator via the high-
pressure gas inlet. There it flows through the two
hollow pistons to the right-hand side of the disks.
The rising pressure that acts on the disks presses
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them together with the pistons to the left against the

flow of natural gas and against the spring force.

S425_026
Disk
Spring

Natural gas pressure

Tank after 1st reduction stage
The natural gas pressure is 20 bar behind the pressure sensor G400 approx. 20 bar
hollow piston.
Transverse passage
to tank pressure
If the pressure on the right-hand side of the disk sensor G400
is approximately 20 bar, the hollow piston rests
High-pressure
against the seal and no more gas can be delivered.
area
The natural gas pressure is reduced to approx. 20 bar
in the first reduction stage.

The transverse passage leads to the tank

pressure sensor. It measures the pressure
in the natural gas tanks and recognises
whether natural gas has been topped up. S425_027

Seal

20
 2nd reduction stage

Regulation of natural gas pressure to 5 - 9 bar

In the second reduction stage, the natural gas pressure is regulated electronically to 5 - 9 bar by the high-pressure
valve for gas mode. The pressure is measured in the low-pressure natural gas system by the gas rail sensor G401.

Transfer from
reduction stage 1, Low-pressure area
The natural gas pressure is approx. 20 bar in front approx. 20 bar
of the high-pressure valve for gas mode.

The first and second reduction stages are connected

to each other via a duct. This means that a pressure of
approx. 20 bar is applied at the high-pressure valve
for gas mode.
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Valve ball S425_050

Valve ball seat Ball guide Valve needle High-pressure valve

for gas mode N372

Regulation of natural gas pressure at 5 - 9 bar

Low-pressure
To regulate the natural gas pressure at 5 - 9 bar, the gas outlet
to engine
high-pressure valve for natural gas mode is activated
by the engine control unit with a pulse-width
modulation signal (PWM signal). The valve needle is
shifted and the valve ball moves out of its seat. The
gas can now flow until the necessary pressure is
reached in the low-pressure natural gas system.

S425_051

In-flow of natural gas High-pressure valve

for gas mode N372

21
 Engine Management

Dash panel insert

The following instruments and warning lamps are provided for natural gas mode and petrol mode in the dash
panel insert:

● Analogue natural gas gauge G411 ● Natural gas mode warning lamp K192
● Analogue fuel gauge G1 ● Reserve fuel warning lamp K105
● Multifunction display

The natural gas gauge has replaced the coolant temperature gauge.

● The coolant temperature warning lamp K43 is illuminated with ignition “on” and switched off at a coolant
temperature of 45 °C.
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● The coolant temperature and coolant shortage warning lamp K28 is illuminated for 3 seconds after ignition “on”
and is switched on again from a coolant temperature of 124 °C as a warning.

Multifunction display
Coolant temperature and Coolant temperature
coolant shortage warning K28 warning lamp K43

S425_028

Natural gas mode Reserve fuel warning

warning lamp K192 lamp K105

Natural gas gauge G411 Fuel gauge G1

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 Instruments and warning lights in dash panel insert

Natural gas gauge G411 (analogue)

- The natural gas gauge shows the current natural gas supply in the natural gas
tanks.

S425_033

Fuel gauge G1 (analogue)

- The fuel gauge shows the current petrol supply in the fuel tank.

S425_034

Natural gas mode warning lamp K192

- The green warning lamp for natural gas mode indicates that the vehicle is
running in natural gas mode.
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S425_033

Reserve fuel warning lamp K105

- The yellow reserve fuel warning lamp is illuminated only when both fuel types
are on at least reserve.
That means that the pressure in the natural gas tanks is less than 30 bar and
less than 7 l of petrol are in the tank.
S425_035 S425_036

Multifunction display MFD

In natural gas mode, the filling levels, ranges and consumption are displayed in the following ways:

- “Please refill natural gas!”
- “Petrol mode: Please refill natural gas.”
- “Please refuel.”
- “Gas start: Please refill petrol.”
Natural gas and petrol are on reserve.
When switching to petrol mode, and petrol supply more than reserve
When switching to petrol mode, and petrol supply on reserve
Vehicle should have started in petrol mode, but this was not possible
because the petrol has been used up. Therefore the engine is started in
natural gas mode.

A single gong sounds with each of these warnings.

Further warnings in natural gas mode include the CNG range (Compressed Natural Gas) in km, the current
consumption at speeds below 3 km/h in kg/h and the current consumption and average consumption at speeds above
3 km/h in kg/100 km.

The range is displayed only for the current mode. If the vehicle starts in petrol mode because the coolant temperature
is below 10 °C or the vehicle has been refuelled, no remaining range is displayed.

23
 Engine Management

Functional diagram
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Legend

A Battery J519 Onboard supply control unit

G1 Fuel gauge J533 Data bus diagnostic interface
G400 Tank pressure sensor J623 Engine control unit
G401 Gas rail sensor J908 Gas shut-off valve relay
G411 Natural gas gauge K105 Reserve fuel warning lamp
J271 Motronic current supply relay K192 Natural gas mode warning lamp
J285 Control unit in dash panel insert N361 Valve 1 for tank shut-off
J329 Terminal 15 voltage supply relay N362 Valve 2 for tank shut-off

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ProCarManuals.com

S425_024

N363 Valve 3 for tank shut-off Input signal

N366 Gas injection valve 1 Output signal
N367 Gas injection valve 2 Positive
N368 Gas injection valve 3 Earth
N369 Gas injection valve 4 CAN data bus
N372 High-pressure valve for gas mode Diagnosis connector
S Fuse

25
 Service

Special tools
Description Tool Application

T50025 Wrench for removing and fitting the tank shut-off valves
Special wrench for
tank valve
S425_058

T50026 Hand wheel for mechanically closing the tank shut-off

Hand wheel valves.

S425_059

VAS 6131/15 The two rear natural gas tanks are removed together with
Mounting set their mountings. The natural gas tanks are removed with
for natural gas tank the scissor-type assembly platform VAS 6131 A.
The mounting set prevents the mountings and natural gas
S425_060 tanks falling during removal.
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Special features of natural gas vehicles

The pressure in the natural gas tanks should be 200 bar maximum when the temperature of the natural gas tanks
and the natural gas is 15 °C. Since the pressure in the natural gas tanks vary depending on the ambient
temperature and the compression heat which occurs during refuelling, a higher pressure may be applied for filling
using a calculation model. After cooling to 15 °C, this pressure should be 200 bar. The natural gas mass filled in kg,
not the filling pressure, is decisive for the driver.

The natural gas tanks and the natural gas heat up during refuelling. If you then park the vehicle, both will cool
down and the pressure in the natural gas tanks will decrease. As a result, the natural gas gauge may show a lower
filling level than before the vehicle was parked.

At low temperatures or after refuelling, the engine is always started in petrol mode. This can lead to petrol
gradually being consumed even though the natural gas supply was never completely used up.

There are two natural gas qualities, natural gas H and natural gas L. Natural gas H has a higher methane content
and thus a higher heating value, which leads to a lower fuel consumption. However, there are also differences
within the quality levels that effect the fuel consumption and the range.
You can recognise the natural gas quality in display group 243, field 4. The value 1.00 stands for natural gas H with
the best quality and 1.29 for natural gas L with the poorest quality.

26
 Test Yourself

Which answers are correct?

One or several of the given answers may be correct.

1. To which gas pressure does the electronic gas pressure regulator in the Passat TSI EcoFuel regulate the
low pressure?

a) It regulates to a natural gas pressure between 5 and 9 bar (absolute).

b) It regulates at a constant 6 bar natural gas pressure.

c) It regulates to a natural gas pressure that corresponds with that of the petrol direct injection.

2. What does the green warning lamp on the natural gas gauge in the dash panel insert indicate?
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a) The green warning lamp indicates that sufficient gas and petrol is available.

b) The green warning lamp indicates that the engine is running in natural gas mode.

c) The green warning lamp indicates that there is no fault in the natural gas system.

3. Which statement about the starting strategy is correct?

a) If there is sufficient natural gas in the natural gas tanks, the engine will always be started in natural gas
mode.

b) The system only switches to natural gas mode when the coolant temperature reaches 60 °C.

c) The engine is started in natural gas mode if there is sufficient natural gas pressure, the coolant temperature
is more than 10 °C and natural gas has not been refuelled since the last time the engine was run.

4. How does the engine control unit recognise that the vehicle has been refuelled and what natural gas
quality is in the natural gas tanks?

a) The gas rail sensor signals that the vehicle has been refuelled and the natural gas quality is recognised via
the Lambda control.

b) The tank pressure sensor signals that the vehicle has been refuelled and the natural gas quality is
recognised via the Lambda control.

c) The system does not need to recognise that the vehicle has been refuelled or detect the natural gas quality
because the natural gas quality is always the same.

1. a; 2. b; 3. c; 4. b
Answers:

27
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© VOLKSWAGEN AG, Wolfsburg

All rights and rights to make technical alterations reserved.
000.2812.19.20 Technical status 03.2009

Volkswagen AG
After Sales Qualifizierung
Service Training VSQ-1
Brieffach 1995
D - 38436 Wolfsburg

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