Self-Study Programme 425 EcoFuel natural gas drive with 1.4L 110 kW TSI engine.pdf

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Service Training
Self-study Programme 425
EcoFuel Natural Gas Drive
with 1.4 l 110 kW TSI Engine
Design and Function
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 (CO
2
)
by 25 %.
The Passat TSI EcoFuel with 7-speed dual clutch gearbox therefore produces just 119 g/km of CO
2
in natural
gas mode.
Furthermore, the exhaust gases produced in natural gas mode do not contain sulphur, soot or fine dust.
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
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
In natural gas operation, consumption
of 4.4 kg natural gas H
*
every 100 km and
a range of approx. 480 km
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
*
Natural gas H (high) has a higher methane
content than natural gas L (low). The higher
the methane content, the better the natural
gas quality and the greater the range.
-
-
Electronic gas pressure regulator with
high-pressure valve for gas mode N372
and Tank pressure sensor G400
S425_002
S425_063
Gas fuel rail with gas injection
valves 1 - 4 N366 - N369 and
gas rail sensor G401
Gas shut-off
valve relay
J908
S425_055
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
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

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