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EcoFuel Natural Gas Drive in Touran and Caddy
Service Training
Self-study Programme 373
EcoFuel Natural Gas Drive
in Touran and Caddy
Design and Function
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Why natural gas?
Driving with natural gas relieves the burden on the
environment.
The emissions of carbon monoxide and nitrogen oxide
are reduced by over 50%. Furthermore, when natural
gas is burnt, the amount of carbon dioxide produced
is 20-25% less than with conventional petrol engines.
This self-study programme describes the design and
function of vehicles for natural gas operation. The
petrol mode in natural gas vehicles is only slightly
different to when you drive vehicles that run
exclusively on petrol.
Also, from an economic viewpoint, driving a natural
gas vehicle is a serious alternative because of the
rising petrol and diesel prices.
You will find basic information on the topic of natural gas in
self-study programme no. 262 “Natural gas — an alternative fuel for motor vehicles”.
S373_064
NEW
Important
Note
The self-study programme shows 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.
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Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Vehicle population . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Service station network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Natural Gas Drive Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Touran EcoFuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Caddy EcoFuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Engine Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
The 2.0l/80kW natural gas engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Natural Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Natural gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Natural gas system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
High-pressure side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
From high pressure to low pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Low-pressure side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Engine Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Engine control unit J623 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Dash panel insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Safety Concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Natural gas system safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Functional Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Touran functional diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Natural gas tank labelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Test Yourself . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
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Introduction
Vehicle population
There are currently around 0.5 million natural gas vehicles in Europe.
Italy accounts for over 430,000 of these natural gas vehicles.
Vehicle population in Europe
7, 0 0 0
900
600
39,100
300
7, 9 0 0
S373_062
400
300
800
400
430,000
The Caddy and Touran EcoFuel will be launched in the following European countries in 2006:
-Belgium
-Denmark
-Germany
-Etonia
-Finland
-France
- Greece
-taly
-Latvia
-Lthuania
-Luxembourg
- Netherlands
-Auia
-Poland
-Potugal
-Sweden
-Slovakia
-Slovenia
-Spain
-Hungary
-Czech Repubic
Bulgaria and Rumania will follow in 2007.
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Service station network
The development of the network across Europe is varied.
In Italy, Switzerland and Germany, the supply of natural gas vehicles is not a problem. There are already over
660 natural gas garages in Germany. That should rise to 1,000 garages by the end of 2007. Drivers looking for
natural gas garages can use special guide maps or, in Germany, for example, a national text message service that
informs the driver about the nearest natural gas garage in relation to his location.
2
4
45
4
4
25/10*
16
2
30
8
>660
9/10*
4
1
3/7*
16
26/79*
S373_061
130
28/40*
4
5**
> 100
10*
600
3/7*
1
* non-publicgarages
** only for buses
You will find further information and addresses of natural gas garages in Germany on the Internet
at www.erdgasfahrzeuge.de and www.gibgas.de.
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