Self Study Programme 621

For internal use only

Audi A3 Sportback g-tron

Audi
Service Training
The Audi A3 Sportback g-tron showcases state-of-the-art CNG The engine in the Audi A3 Sportback g-tron is based on the 90 kW
drive technology, starting with the fuel storage. Its two tanks 1.4 TFSI. Modifications were made to the cylinder head, turbo-
under the luggage compartment floor can each hold 7.2 kg of charging, injection system, and the catalytic converter. Developing
CNG at a maximum 200 bar pressure referred to 15 °C. 81 kW (110 hp) and 200 Nm of torque, the Audi A3 Sportback
In keeping with Audi's ultra-lightweight construction principle, g-tron has a top speed of 190 kph, with 0 to 100 kph taking eleven
each tank weighs 27 kg less than its conventional steel counter- seconds. The five-door model consumes on average less than
part. The CNG tanks made from an enhanced plastic matrix. A 3.5 kg per 100 km of CNG. CO2 tailpipe emissions are less than
gas-impermeable polyamide polymer forms the inner layer, while 95 grams per km in gas mode.
a second layer of carbon fiber-reinforced polymer (CFRP) gives the
tank its extremely high strength; a third layer of glass fiber rein-
forced polymer (GFRP) provides protection against exterior
damage. High-strength epoxy resin is used to bind the fibre-
reinforced materials.
The electronic gas pressure regulator reduces the high pressure of
the gas flowing from the CNG tanks down to around five to nine
bar in two stages. This ensures that the right pressure is always
present in the injector rail and at the injector valves. If the pressure
in the CNG tanks drops below the required level, the engine man-
agement system automatically switches to petrol operation. After
e-media
refueling, and whenever it is very cold, the engine is started with
petrol initially, then it switches over to CNG. This SSP contains QR codes which you can
use to access additional interactive
content see page 39.

621_004

Learning objectives of this self study programme:

This Self-Study Programme provides you with information about • What are the components of the CNG system?
the CNG system in the Audi A3 Sportback g-tron. Once you have • How is authorised to carry out work on the CNG system?
completed this Self Study Programme you will be able to answer • How do you identify an Audi A3 Sportback g-tron?
the following questions:

!
Note
The graphics and illustrations shown in this self study programme are basic representations and are given to help understand
concepts.

2
 Contents

Introduction
Qualification __________________________________________________________________________________________________________________________________________________ 4
Natural gas ___________________________________________________________________________________________________________________________________________________ 5
Audi e-gas project ____________________________________________________________________________________________________________________________________________ 6
Vehicle distinguishing features _____________________________________________________________________________________________________________________________ 8

Engine mechanicals
1.4l TFSI engine of the EA211 series (81 kW) ___________________________________________________________________________________________________________ 10
Comparison of torque/power curves ______________________________________________________________________________________________________________________ 11

CNG drive
Overview _____________________________________________________________________________________________________________________________________________________ 12
CNG filler neck _______________________________________________________________________________________________________________________________________________ 14
CNG lines _____________________________________________________________________________________________________________________________________________________ 15
Distributor with non-return valve _________________________________________________________________________________________________________________________ 15
CNG tank _____________________________________________________________________________________________________________________________________________________ 16
Tank shut-off valves _________________________________________________________________________________________________________________________________________ 19
Gas pressure regulator _____________________________________________________________________________________________________________________________________ 24
Gas distributor rail __________________________________________________________________________________________________________________________________________ 29

Engine management system

Sensors and actuators ______________________________________________________________________________________________________________________________________ 30
Engine management control unit J623 ___________________________________________________________________________________________________________________ 32
Operating strategy __________________________________________________________________________________________________________________________________________ 32

Displays
Instrument cluster __________________________________________________________________________________________________________________________________________ 34

Service
Special tools and workshop equipment ___________________________________________________________________________________________________________________ 35

Annex
Test your knowledge ________________________________________________________________________________________________________________________________________ 37
Self Study Programmes ____________________________________________________________________________________________________________________________________ 39
Information on QR codes ___________________________________________________________________________________________________________________________________ 39

!
The Self Study Programme teaches a basic knowledge of the design and mode of operation of new models,
new automotive components or new technologies. Note
It is not a Repair Manual! Figures are given for explanatory purposes only and refer to the data valid at the
time of preparation of the SSP. This content is not updated.
For further information on maintenance and repair work, always refer to the current technical literature. Reference

3
Introduction

Qualification
Special qualifications are required to be able to service and provide
technical support for the Audi A3 Sportback g-tron within the Audi
organisation. Given the different requirements and regulations
relating to the handling of CNG-powered vehicles, it is necessary to
provide basic qualification in accordance with the national regula-
tions in force in your country.
For information on specific qualification requirements, please
contact the relevant authorities and institutions in your country.
For the purposes of qualification within the Audi organisation,
AUDI AG will provide importers with an expert training module
covering the special technology of the Audi A3 Sportback g-tron.

Instruction

!
In some countries, employers are obligated to exercise due care by advising employees of workshop hazards and provide
instruction.
Even in countries where this obligation does not apply, AUDI AG requires that employers provide instruction.
Personnel who carry out work on an Audi A3 Sportback g-tron, but not on the gas system,and/or are entrusted with handling
an Audi A3 Sportback g-tron, must have received instruction.
Country-specific regulations must be observed.

Training

!
Work on the gas system in an Audi A3 Sportback g-tron may only be performed by specially trained personnel and at suitable
workstations!
Country-specific regulations must be observed and the AUDI AG expert training module completed.

Maintenance and repair

!
All service work on the Audi A3 Sportback g-tron must be carried out as specified in ELSA and in the Offboard Diagnosis Infor-
mation System.

4
Natural gas
Natural gas is a colourless, odourless and flammable fossil-based Odorant that is added to natural gas so that it can be detected.
gas found in deep underground rock formations. Natural gas forms This process is referred to as odorization.
naturally in much the same way as petroleum.
Natural gas is a mixture of various gases, the main ingredient In gas mode, the Audi A3 Sportback g-tron runs on compressed
being methane. Natural gas is classified as high-calorific (H-gas natural gas or CNG.
or High gas) and low-calorific gas (L-gas or Low gas) based on its The vehicle's CNG consumption can vary in practice due to the
methane content. difference in the quality of H-gas and L-gas.
H-gas contains over 87 vol. % methane and L-gas less than
87 vol. % methane.
Modern science has now found a way to produce natural gas
synthetically.

Natural gas quality

The following table provides a summary of the various natural gas

quality levels. The values given are approximations and can vary
depending on country of origin and production site.

H-gas (North Sea) H-gas (Russia) L-Gas (Germany)

Calorific value in kWh/m3 11.1 10.0 8.9

Methane (CH4) in vol. % 87.1 97.8 86.8

Ethane (C2H6) in vol. %

Propane (C3H8) in vol. % 9.9 1.3 6.7
Butane (C4H10) vol. %
Inert gases in vol. % 3.0 0.9 6.5

Comparison of the physical and technical properties of natural gas and petroleum

Natural gas, H-Gas, gaseous Petroleum, liquid

Average density in kg/l 0.155, at a pressure of 200 bar 0.75

Calorific value in kWh/kg 12.5 11.4

Delivery required in l/kg 6.15, at a pressure of 200 bar 1.33

RON 130 95

Ignition temperature in °C approx. 600 approx. 200 – 300

One litre of petroleum has the same range as 4.1 litres of CNG. Outflowing CNG can form a potentially explosive gas-air mixture in
Whereas one litre of petroleum weighs 0.75 kg, 4.1 litres of CNG the atmosphere. An atmospheric CNG concentration of
weigh only 0.64 kg. approx. 4 vol. % to 17 vol. % represents an explosion hazard.

5
Audi e-gas project
In the course of its e-gas project, Audi will develop an entire chain
of sustainable energy carriers. The chain begins with electricity
produced from renewable energy sources, and has hydrogen and
synthetic Audi e-gas as its end products. Construction of an indus-
trial plant to produce synthetic methane (e-gas) from CO2 and
renewable electricity has been completed in Werlte (Emsland
district of Lower Saxony), Germany. In the first stage of the
process, the Audi e-gas plant uses the renewable electricity for
electrolysis – splitting water into oxygen and hydrogen (Audi
e-hydrogen), which could one day be used to power fuel-cell
vehicles.
Because there is not yet a widespread infrastructure, there now
follows a second process stage in which synthetic renewable
methane – Audi e-gas – is produced by the reaction of hydrogen
with CO2 in the methanisation plant. It is chemically identical to
fossil-based natural gas and can be distributed to CNG filling
stations via the natural gas grid.
Thanks to this power‑to-gas process, the electricity grid and gas
grid are being linked bidirectionally for the first time. Until now
while you could generate electricity from gas, the reverse was not
possible.

Wind power
The primary objective of the
Audi e-gas project is to promote
the use of renewable power.

Power grid
The wind power is fed into
the public power grid.

Electrolysis
The electrolysis plant uses electric-
ity produced from wind turbines to
split water molecules into hydro-
gen and oxygen.

6
 Audi e-gas plant

The Audi e-gas plant paves the way for tapping into the natural-gas
network with its huge capacity as a storage and transport system
for hitherto excess electricity capacity. The CO2 used in the Audi
e-gas plant is a waste product from a nearby biogas plant operated
by the utility EWE.
The CO2, which would otherwise pollute the atmosphere, is bound
into the fuel at the Audi e-gas plant. The e-gas plant will annually
produce about 1,000 metric tons of e-gas and will bind some
2,800 metric tons of CO2. This corresponds roughly to the amount
of CO2 that 224,000 beech trees absorb in a year.

Power supply Methanisation plant

Gas feed-in into the public

gas grid

Electrolysis

Amine scrub- 621_002

bing

Gas grid
The e-gas is stored in the public gas network, thus also enabling households
and industry to be supplied with energy from renewable sources.

CNG filling station

The increasing proportion of e-gas facilitates
climate-friendly long-distance mobility.

Methanisation
The hydrogen reacts with carbon
dioxide in a methanisation plant.
End product: e-gas (synthetic natural gas).

621_003

7
Vehicle distinguishing features
g-tron logo on the boot lid Boot floor

Cover of CNG tank and CNG filler neck and petrol filler neck
bumper without visible exhaust

8
g-tron logo on the selector lever and on the dash panel g-tron logo on the dash panel insert and
on the CNG fuel gauge

621_019

g-tron logo on the wings g-tron logo on the design cover in the engine bay

9
Engine mechanicals

1.4l TFSI engine of the EA211 series (81 kW)

The elevated combustion pressure and combustion temperatures
in the engine during gas operation put more stress on the engine.
Moreover, the gas does not have the lubricating and damping
properties of the petrol additives which protect the engine against
mechanical overload at high rpm.
Therefore, the following mechanical components of the engine
block have been modified:

• Valve seat rings

• Intake/exhaust valves
• Piston rings
• Camshafts

The following add-on engine parts have also been adapted:

• Spark plugs
• Turbocharger
• Intake manifold
• Catalytic converter

621_065

Valves, valve guide and valve seat rings Turbocharger

The following modifications were made on the intake end for gas The exhaust gases flow more slowly during gas operation. This
operation: would normally cause the compressor impeller to spool up more
• Nitride-hardened valves slowly at low rpm.
• Valve guide is made from a more highly wear resistant To avoid turbo lag, therefore, a smaller compressor turbine is used.
material The (exhaust) turbine wheel has the same diameter as that of the
• Valve seat ring is made from a more highly wear resistant 90 kW 1.4l TFSI engine.
material

The following modifications were made on the exhaust end for gas
operation: Intake manifold
• Nitride-hardened valves
• Valve seat ring is made from a more highly wear resistant Mountings were added to the intake manifold for the gas injector
material valves.

Piston rings

The upper piston rings are PVD (Physical Vapour Deposition) coated
to protect them against wear during gas operation.
Camshafts
To reduce valve seating velocity, the descending cam lobes have a
flatter design.
Spark plugs
The emissions stemming from CNG combustion are more aggres-
sive than those stemming from petrol combustion. Therefore, the
spark plug housing and the screw-in thread require a different type
of coating.
Catalytic converters
In terms of their basic design, the exhaust gas aftertreatment
systems for petrol and CNG engines are similar. However, when
running a vehicle on CNG (CH4) a higher temperature is required to
convert the unburnt hydrocarbons. This can only be achieved by
increasing the precious metal load in the catalytic converter by a
factor of 2 – 2.5. The catalytically active surface area of both
catalytic converters is large enough to fully convert the hydrocar-
bons (CH4) in the exhaust gas at maximum exhaust gas flow (full
throttle).
What is meant by "conversion" is that the unburnt hydrocarbons
contained in the exhaust gas are chiefly converted in the catalytic
converter to CO2 and H2O when they react with the catalytic layer in
the presence of oxygen.

Reference
For further information about the function and design of the basic engine, refer to Self Study Programme 616 "Audi 1.2l and
1.4l TFSI engines of the EA211 series".

10
Comparison of torque/power curves

Engine code CMBA (basic engine) Engine with engine code CPWA (CNG engine)

Power in kW Power in kW

Torque in Nm Torque in Nm

Engine speed [rpm] Engine speed [rpm]

621_005 621_006

Engine code CMBA CPWA

(basic engine) (CNG engine)
Type Four-cylinder in-line engine Four-cylinder in-line engine

Displacement in cm3 1395 1395

Power output in kW (hp) at rpm 90 (122) at 5000 - 6000 81 (110) at 4800 – 6000

Torque in Nm at rpm 200 at 1400 - 4000 200 at 1500 - 3500

Number of valves per cylinder 4 4

Firing order 1–3–4–2 1–3–4–2

Bore in mm 74.5 74.5

Stroke in mm 80 80

Compression ratio 10 : 1 10 : 1

Engine management system Bosch MED 17.5.21 Bosch MED 17.5.21

Fuel Premium unleaded 95 RON Compressed natural gas (CNG) and premium
unleaded petrol (95 RON)
Exhaust emission standards EU 5 plus EU 5 plus

Vehicle use A3 '13 A3 Sportback g-tron

11
 CNG drive

Overview
In the Audi A3 Sportback g-tron, CNG mode is the priority drive
mode. This means that the engine always starts and runs in CNG
mode, provided that all the requirments for CNG operation have
been met.
The driver can switch back and forth between both operating
modes.

Low-pressure CNG line

Plastic lines High-pressure CNG line

Gas pressure regulator with (petrol)
tank pressure sensor G400 and
high-pressure valve for gas operation N372

Decoupling element Underbody catalytic converter

!
Note
The pressure in the high-pressure CNG line must be relieved before carrying out work on the CNG system. The instructions
given in ELSA and in the Offboard Diagnosis Information System must always be followed by service personnel.

12
 Petrol tank filler neck

CNG filler neck

Distributor with non-return valve CNG tank

621_064

Guard plate Tensioning strap Plastic cover

Silencer Fuel tank Exhaust tailpipe in front of rear axle

(petrol)

!
Note
Even if the engine has changed over from CNG mode to petrol operation because the CNG has run out, a residual amount of
CNG still remains in the CNG tanks.

13
CNG filler neck
The CNG and petrol tank filler necks are located on the right-hand
side of the vehicle under the fuel filler flap.

621_018
Petrol tank filler neck
CNG filler neck

Non-return valve with filter

A non-return valve with filter is integrated in the CNG filler neck.
When the tank is filled, the non-return valve is opened against the
force of the spring by the inflowing gas. The gas flows into both
CNG tanks at a pressure of up to 260 bar. Any coarse particles in
the CNG are removed by the filters.
Once filling has been completed, the gas pressure is identical
before and after the non-return valve. The non-return valve is now
closed again by the spring.

Spring

Non-return valve 621_021 621_022

open Filter Non-return valve
closed
Inflowing CNG To distributor

The filter in the CNG filler neck is cleaned by the reduction in

pressure which takes place when the filler coupling is removed
from the CNG filling system. This means that the filter is mainte-
nance free. It must also be ensured that the ring seal in the CNG
filler neck is still in its correct position.

621_023
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Seal ring
Animation showing the gas filler neck.

14
CNG lines
All CNG lines on the high-pressure side are made from stainless
steel and have an outer diameter of 6 mm.

Double-clamp ring fitting

The CNG lines are connected to other components by means of a When the union nut is tightened, the rear clamp ring is pushed
double-clamp ring fitting. under the front clamp ring and thus provides additional sealing.
This type of fitting ensures that the tank is gas impermeable.

Loose double-clamp ring fitting Tightened double-clamp ring fitting

Rear Rear
clamp ring clamp ring

621_024 621_025

Stainless steel Union nut Front Union nut Front

pipe clamp ring clamp ring

Distributor with non-return valve

The distributor with non-return valve serves as a central gas
distributor unit. Two high-pressure CNG lines branch from here to
the CNG tanks - one to the gas pressure regulator and one to the
CNG filler neck. The non-return valve is built into the connection
for the CNG line from the CNG filler neck. After refuelling has been
completed, therefore, two non-return valves seal off the gas
system.

Distributor with non-return valve

621_026

To
CNG tank

To To
CNG tank gas pressure
regulator

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Animation showing the distributor.

Non-return valve

From
CNG filler neck
621_027

15
CNG tank
The Audi A3 Sportback g-tron is equipped with two identical CNG
tanks in addition to the petrol tank. Both CNG tanks are securely
attached to a rack by means of tensioning straps. This rack is, in
turn, bolted to the car body.
Plastic CNG tanks are used on the Audi A3 Sportback g-tron. Each
individual fuel tank weighs approx. 16 kg and therefore is approx.
27 kg lighter than an equivalent steel CNG tank. The CNG tank has
a capacity of approx. 46 litres. This corresponds to a weight of
approx. 7.2 kg at a filling pressure of 200 bar and a temperature of
15 °C.

621_028
Plastic cover Guard plate Tensioning strap CNG tank Tank shut-off valve

Protective rubber strip

When filling and draining the tank, however, the diameter of the
CNG tank can vary by up to 2 mm during operation due to tempera-
ture fluctuation. To protect the CNG tanks from damage due to
expansion and contraction, it is necessary to place a protective
rubber strip between the CNG tanks, the tensioning straps and the
rack.

Tensioning strap 621_029

Protective rubber strip

!
Note
The instructions given in ELSA and in the Offboard Diagnosis Information System must always be followed by service person-
nel when carrying out work on the CNG system.

16
CNG tank

The CNG tanks on the Audi A3 Sportback g-tron are made from a The outer layer of glass fiber-reinforced polymer (GFRP) provides
plastic matrix. The inner layer consists of gas-impermeable polya- robustness and protects the tank against damage.
mide polymer, while a second layer of carbon fiber-reinforced A high-strength epoxy resin serves as a binder for the fibre-based
polymer (CFRP) gives the tank strength. materials.

621_030

Inner layer:
Gas-impermeable poylamide

Middle layer:
Carbon fibre-reinforced polymer (CFRP)

Outer layer:
Glass fibre-reinforced polymer (GFRP)

Distributor with non-return valve

Tank shut-off valve

17
Infomation displayed on the CNG tank

621_031

Key:

Number Marking (definition)

1 User only manufacturer-approved pressure relief device

2 ECE Type approval number: E13 110 R-000241

3 Month/Year of approval: 12 / 2012

4 Date of first pressure test: 07 / 2013

5 Working temperature: TS -40 °C / 65 °C

6 Working pressure: 20 MPa/15 °C

(20 MPa at a temperature of 15 °C)
7 ID number: AH_314_HY_1c

Filling information: CNG ONLY

8
CNG Type 4 (fully fibre-reinforced pressure vessel with plastic liner)
9 Serial number: 0000820/13

10 Test pressure: 30 MPa

11 Volume: 46 litres

12 Empty weight: 14.50 kg without tank shut-off valve

13 Maximum tightening torque for tank shut-off valve: 130 Nm

14 Do not use after: 07 / 2033

(service life of CNG tank)

18
Tank shut-off valves
Electrical tank Manual
Each CNG tank is fitted with a tank shut-off valve which is bolted shut-off valve tank shut-off
into the CNG tank.
The tank shut-off valves are so-called safety valves.

The tank shut-off valve comprises the following components:

• Electrical tank shut-off valve

• Manual tank shut-off device
• Thermal cut-out
• Flow control
• Connections for CNG line

Thermal cut-out
621_032
Connection for CNG line

Electrical connection

Manual Connection for CNG tank Electrical tank shut-off valve

tank shut-off with flow limiter

621_033

Thermal cut-out Connection for CNG line Electrical connection

19
Tank shut-off valves 1 and 2 N361 and N362

Each of the two tank shut-off valves has an electrically actuated

valve. These are tank shut-off valves 1 and 2 N361 and N362.
In the de-energised state, the valve spring pushes against the
valve seat and thereby seals it, shutting off the gas flow from the
CNG tank.

621_034

Tank shut-off valve 1 N361 or

tank shut-off valve 2 N362

When the magnetic coil of the valve is energised, the valve opens
against the pressure of the valve spring and CNG operation is again
possible.
At the same time, tank shut-off valves 1 and 2 N361 and N362
receive voltage from the relay gas shut-off valves J908. Relay J908
is, in turn, controlled by control unit J623.

621_035

Valve Valve spring Magnetic field

e-media

Animation showing the tank shut-off valve

in operation

20
Filling the tank

When the vehicle is refuelled, the inflowing CNG exerts up to

approx. 260 bar of pressure on the valve springs of the valve seat.
The CNG is now able to flow into the CNG tank. Once refuelling has
been completed, the inflowing CNG comes to a standstill. The
valve spring now pushes the valve against the valve seat again,
thereby closing the valve.

e-media

Animation showing the refuelling process.

621_036

Inflowing CNG Open valve Valve spring

compressed up to
260 bar

Manual tank shut-off device

Manual tank shut-off device
The anual tank shut-off device allows the tank shut-off valves to
close mechanically.
It is possible to run the vehicle on CNG as long as the tank shut-off
valves are manually closed.

Please note in particular:

The manual tank shut-off device does not seal off the channel to
the thermal cut-out.
When the thermal cut-out is activated, the CNG flows freely out of
the CNG tank. This prevents the CNG tank from bursting under
exposure to intense heat despite the fact that the tank shut-off
valve is closed.

621_037

Manual tank shut-off valve

closed

Channel to eletrtical tank shut-off valve

closed

Channel to thermal cut-out

Thermal cut-out

e-media

Animation showing the manual tank shut- 621_038

off device.

21
Thermal cut-out

The thermal cut-out is a key component of the tank shut-off valves.

The channel to atmosphere is closed by a metal body with fusible

link.

621_039

Fusible link Channel leading to

atmosphere closed

If the thermal cut-out is heated at a temperature above 110 °C for

a defined period of time, the fusible link begins to melt and the
channel opens. The CNG from the CNG tank can only escape to
atmosphere at a reduced rate.
The thermal cut-out prevents the CNG tank from bursting under
exposure to intense heat.

621_062

Channel leading to
atmosphere open

e-media

Animation showing the thermal cut-out.

22
Flow control

Flow rate is computed by a mechanical safety function of the tank

shut-off valves. The connecting flange for the CNG tank houses an
additional valve: the flow limiter valve.

621_040

Connecting flange Flow limiter

for CNG tank

The task of a flow limiter is to prevent uncontrolled discharge of

CNG from the CNG tank in the event of a sudden loss of pressure
on the high-pressure side.

A sudden loss of pressure can, for instance, occur due to rupturing

of the CNG line.

621_041

The CNG pressure is identical upstream and downstream of the

flow limiter. The valve spring holds the valve in the open position.
If a sudden loss of pressure occurs on the high-pressure side and
the CNG pressure upstream of the flow limiter is approx. 6.5 bar
higher than the pressure downstream of the flow limiter, the valve
will be closed due to the pressure difference.
Because the flow limiter is legally required to have a degree of
leakage, the CNG can only escape from the CNG tank at a greatly
reduced pressure.

After the manual tank shut-off device closes, pressure equalisation 621_042
Sealing face
can take place before and after the flow limiter due to the leakage.
As a result, the flow limiter automatically opens again.

e-media
621_043
Animation showing the flow limiter.
Sealing cone with
leakage port

23
Gas pressure regulator
The gas pressure regulator is located in the engine bay at the front
right and has the task of reducing the pressure of the CNG from
approx. 200 bar to 5 – 9 bar according to requirements.

e-media

Animation showing the gas pressure regu-

lator.

621_044
Gas pressure regulator

The gas pressure regulator consists of the following components:

• Mechanical gas pressure regulator • High-pressure CNG connection

• High-pressure valve for gas operation N372 • Low-pressure CNG connection
• Mechanical pressure relief valve • Coolant connections
• Tank pressure sensor G400

Coolant connections
Low-pressure CNG connection

Tank pressure sensor

G400

High-pressure CNG connection

Mechanical pressure relief valve

High-pressure valve for gas operation

N372

621_045
The figure is shown rotated for better viewing.

24
Mechanical pressure regulator

High-pressure valve for gas operation

N372

Mechanical pressure regu-

lator

621_020
The figure is shown rotated for better viewing.

In the first stage of the process, the mechanical pressure regulator

reduces the pressure of the CNG to approx. 20 bar.

The CNG released from the CNG tanks flows through the high-
pressure connection and into the mechanical gas regulator. In the
rest state, the piston spring lifts the hollow-drilled piston off the
seal. The CNG flows through the hollow piston to the piston crown
side.

621_046

Inflowing CNG High pressure zone

If no CNG is burnt by the engine, the pressure acting on the piston

crown rises to over 20 bar. The pressure of the CNG now displaces
the piston against the force of the piston spring until the piston is
seated on the seal and the channel is shut off.
The CNG no longer flows to the piston crown side.

621_047

CNG pressure over 20 bar

If the vehicle engine is running in CNG mode, the CNG pressure

acting on the piston crown decreases. The piston spring lifts the
piston off the seal. The CNG again flows through the channel to the
piston crown side. During vehicle operation, a gap will occur
between the piston and the seal, thereby setting the pressure on
the piston crown side to approx. 20 bar.

621_048

CNG pressure over approx. 20 bar

25
High-pressure valve for gas operation N372

In the second stage of the process, the high-pressure valve for gas
operation N372 reduces the CNG pressure electronically from
approx. 20 bar to 5 – 9 bar according to requirements.

The reduced CNG pressure of approx. 20 bar is applied to the ball

valve of the high-pressure valve for gas operation N372. If the
high-pressure valve for gas operation N372 is not activated by the
engine control unit J623, the ball valve is closed.

621_049

Transition from reduction stage 1,

approx. 20 bar
Valve ball seat
Valve ball

Low pressure zone

In CNG mode, the engine control unit J623 activates the high-
pressure valve for gas operation N372 by means of a pulse-width-
modulated signal. The valve stem together with the metal core are
lifted by the magnetic coil. The ball valve opens to create a gap.
The CNG flows to the low-pressure side and still has a pressure of
between 5 and 9 bar.

Pulse-width-modulated activation enables the engine control unit

J623 to adapt the CNG pressure on the low-pressure side according
to requirements.

621_050

Valve ball Inflowing CNG

26
Mechanical pressure relief valve

The mechanical pressure relief valve located on the low-pressure The lack of a sealing cap in the gas pressure regulator may indicate
side in the gas pressure regulator is another safety component of that the pressure relief valve has been activated.
the CNG system.

If the CNG pressure on the low-pressure side exceeds approx.

16 bar, the pressure relief valve will open.
This prevents CNG from flowing to the low-pressure side under
excessively high pressure and potentially causing damage.

Low-pressure CNG connection

Mechanical pressure relief valve

The figure is shown rotated for better viewing.

621_051

Coolant connections
Coolant return Coolant flow
Reducing the CNG pressure produces cold.
At very low ambient temperatures, therefore, the temperature in
the gas pressure regulator may drop too quickly and cause mal-
functioning.
To prevent this, the gas pressure regulator is integrated in the
cooling system of the internal combustion engine and therefore is
heated.

621_052

27
Tank pressure sensor G400

The tank pressure sensor G400 is mounted on the gas pressure

regulator and measures the actual CNG pressure on the high-
pressure side during vehicle operation.
The tank pressure sensor consists, among other things, of a sensor
element and evaluation electronics with electrical connections.

621_053

The figure is shown rotated for better viewing.

The sensor element houses a metal diaphragm, to which four

resistors are attached.

Electrical
connection

Sensor element

621_054

The CNG pressure causes the metal diaphragm to bend. The resis- Housing with pressure connection
tors also undergo a change of shape and resistance.

Contact
spring

PCB with evaluation

electronics

621_055
Resistors Metal diaphragm

The evaluation electronics measures the change in resistance and

transmits a corresponding voltage signal to the engine control unit
J623.
Signal output voltage [V]

CNG pressure [MPa]

621_056

28
Gas distributor rail
Injector rail sensor G401
Injector rail sensor
The injector rail sensor G401 is mounted on the gas distributor G401
rail.
During vehicle operation, sensor G401 measures the CNG pressure
within the injector rail on the low-pressure side. In addition,
injector rail sensor G401 measures the temperature of the CNG in
the gas distributor rail.
Both values are sent to the engine control unit J623 as voltage
signals.

621_060

Gas injector valves 1 – 4, N366 – N369

There are four gas injector valves.

Gas injector valve 1 N366, gas injector valve 2 N367, gas injector
valve 3 N368 and gas injector valve 4 N369 are integrated in the
intake manifold. When the gas injector valves are activated by the
engine control unit J623, CNG is injected into the intake manifold
upstream of the injectors.

Gas distributor rail

621_061

e-media

Animation showing the gas distributor

rail.

29
Engine management system

Sensors and actuators

Sensors
Gearbox neutral position sensor G701

Oil pressure switch F22

Oil pressure switch for reduced oil pressure F378

Knock sensor 1 G61

Accelerator pedal position sensor G79

Accelerator pedal position sensor 2 G185

Clutch position sensor G4761)

Brake light switch F

Brake pedal switch F63

Tank pressure sensor G400

Injector rail sensor G401

Engine speed sensor G28 Engine management

control unit
J623
Charge pressure sensor G31
Intake air temperature sensor 2 G299

Brake servo pressure sensor G294

Intake air temperature sensor G42

Intake manifold pressure sensor G71

Fuel pressure sender G247

Low-pressure fuel pressure sender G410

Hall-effect sensor G40

Throttle valve module J338

Throttle actuator position sensors 1+2
for vehicles with electronic accelerator G187, G188

Coolant temperature sensor G62

Coolant temperature sensor at radiator outlet G83

Oil level/temperature sensor G266

Oxygen sensor G39

Oxygen sensor downstream of catalytic converter G130

Wastegate actuator position sensor G581

Auxiliary signals:
−− Cruise control system
−− Speed signal
−− Start request to engine control unit (keyless start 1 + 2)
−− Terminal 50
−− Crash signal from airbag control unit

30
 Actuators
Oil pressure regulating valve N428

Fuel pressure regulating valve N276

Continued coolant circulation pump V51

Oxygen sensor heater Z19

Heater for oxygen sensor 1 downstream of catalytic
converter Z29

Ignition coils 1 – 4 with output stage

N70, N127, N291, N292

Radiator fan control unit J293

Radiator fan V7

Injector, cylinders 1 – 4 N30 – N33

Camshaft control valve 1 N205

Exhaust camshaft timing adjustment valve 1 N318

Activated charcoal canister solenoid valve 1 N80

Throttle valve positioner G186 for electronic power control

Charge pressure actuator V465

Gas injector valves 1 – 4, N366 – N369

Relay for gas shut-off valves J908

Tank shut-off valve 1 N361
Tank shut-off valve 2 N362

High-pressure valve for gas operation N372

Coolant circuit solenoid valve N492

Fuel pump control unit J538

Fuel predelivery pump G6
Fuel gauge sensor G

Auxiliary signals:
−− Automatic gearbox control unit/engine speed
−− ABS control unit/clutch position
−− AC compressor
Key:

New sensors and actuators compared to the 90 kW 1.4l TFSI engine
621_057

1)
only for models equipped with manual gearbox

31
Engine management control unit J623
The engine control unit J623 can run the internal combustion
engine of the Audi A3 Sportback g-tron on both petrol and CNG. If
certain framework conditions are met, the engine control unit J623
will run the internal combustion engine on CNG as a priority.
In addition to the two CNG tanks, the Audi A3 Sportback g-tron is
fitted with a petrol tank which holds approx. 50 litres. Therefore,
the Audi A3 Sportback g-tron is a so-called "bivalent" vehicle.
Vehicles where the capacity of the fuel tank for the secondary fuel
type does not exceed 15 litres are referred to as "quasi-monova-
lent".

621_063

Operating strategy
If terminal 15 is "on", tank shut-off valves 1 and 2 N361 and N362 This ensures a reliable supply of CNG to the gas pressure regulator,
are opened for max. 2 seconds. while tank pressure sensor G400 determines the fill level of the
CNG tank.

Engine start Coolant temperature ≤ -10 °C Coolant temperature > -10 °C

without prior filling with CNG
with prior filling with CNG
• Engine starts in petrol mode • Engine starts in CNG mode
• Engine switches to CNG operation if
heating of the injector valves is complete
• Engine starts in petrol mode • Engine starts in petrol mode
• Engine switches to CNG operation if • Engine switches to CNG operation if the
heating of the injector valves is complete oxygen sensor has been activated
and the oxygen sensor has been acti-
vated

32
Function Description

Adaption of natural gas quality If the engine control unit J623 determines from information supplied by the tank pressure
sensor G400 that the CNG pressure in the CNG tanks has increased by approx. 30 % since
the last time the engine was operated, it assumes that the vehicle has been refuelled with
CNG.
When lambda control is active, natural gas quality is determined for approx. 60 seconds at
medium engine speed and load. During this time, the engine control unit J623 determines
the injection time adaption necessary to achieve a lambda ratio of 1. The engine will start
in petrol mode until adaption of natural gas quality is complete.
CNG temperature Reducing the pressure of the CNG in the gas pressure regulator from 200 bar to 5 – 9 bar
produces cold. To ensure that the temperature of the CNG does not drop below -50 °C on
the exhaust side of the gas pressure regulator, the gas pressure regulator is integrated in
the engine's coolant system.
Gas injector valves 1 – 4 N366 – N369 will only function properly as of a certain tempera-
ture.
CNG high pressure The engine control unit J623 receives information about the CNG pressure on the high-
pressure side from the tank pressure sensor G400. It uses this information to detect refu-
elling of the vehicle with CNG.
To enable the fuel level in the CNG tank to be indicated, the engine control unit J623 uses
the CNG pressure and the ambient temperature to compute how much gas is stored in the
CNG tanks. The engine control unit sends this information to the control unit in the dash
panel insert J285 via CAN bus.
CNG low pressure The injector rail sensor G401 supplies the engine control unit J23 with information about
the pressure and temperature of the CNG in the injector rail. The engine control unit uses
this information to adapt the CNG injection time.
If the CNG pressure in the distributor rail drops 1 bar below the nominal pressure set by
the engine control unit, the engine control unit will change over to petrol operation.
Injection time The opening times of the injector valves are adapted by the engine control unit J623 in a
cylinder-selective fashion.

Primary influencing factors are:

• Engine load
• Engine speed
• Load demanded by customer
• Natural gas quality
• CNG temperature on the low-pressure side
• CNG pressure on the low-pressure side
• Lambda control

Other possible influencing factors:

• Cooling capacity of air conditioning system
• Charging capacity of alternator
Heating the injector valves If the coolant temperature is less than or equal to -10 °C, the engine will start and operate
N366 – N369 in petrol mode. During vehicle operation, gas injector valves 1 – 4 N366 – N369 are subse-
quently activated by the engine control unit J623. Given that tank shut-off valves 1 and 2
N361 and N362 and the high-pressure valve for gas operation N372 are not activated, CNG
can only be injected on the low-pressure side.
If the engine control unit J623 determines from the information supplied by the injector
rail sensor G401 that the CNG pressure is decreasing, it energises gas injector valves 1 – 4
N366 – N369 continuously for approx. 60 to 90 seconds. This heats up the injector valves
and ensures that they function properly. Now the engine control unit J623 is able to switch
to CNG operation.
Diagnostics If the engine control unit J623 detects a malfunction in CNG mode, it automatically
switches to petrol operation.
The engine control unit carries out a repeat system test whenever the engine is restarted.
The engine control unit J623 does not allow the engine to run in CNG mode as long as the
system malfunction is active (static).
If the status of the system malfunction changes from active to passive (sporadic), or if the
cause of the malfunction has been rectified, CNG operation will again be possible.

33
Displays

Instrument cluster
The dash panel insert on the Audi A3 Sportback g-tron has been In addition, the driver information system has been upgraded to
adapted for CNG operation. provide, among other things, information on average fuel con-
sumption, current fuel consumption and remaining range in CNG
A CNG fuel gauge keeps the driver informed about the current fill mode.
level in the CNG tanks.
In addition, the driver is informed via the warning lamp for CNG
operation that the internal combustion engine is running on CNG.

621_007

Indicator lamp for CNG mode Fuel gauge for CNG Fuel gauge for petrol

Reference
For further information about the displays in the dash panel insert and in the driver information system, refer to the vehicle
Owner's Manual.

34
 Service

Special tools and workshop equipment

VAS 6227 Gas leak detector for CNG powered vehicles V.A.G 1274B/12 Adapter for cooling system tester

621_009

621_008

T10349 Magnetic release tool T50026 Hand wheel

621_010 621_011

T50025 Wrench

621_012

!
Note
Information on the correct use of special tools and workshop equipment can be found in ELSA.

35
T10521 Insert tool, 17 mm T10522 Insert tool, 22 mm

621_013 621_015

T40173/2 Adapter T40173/3 Padding

621_014 621_016

T10523 Tensioning strap

621_017

!
Note
For further and up-to-date information on the special tools and workshop equipment, refer to the Workshop Equipment
catalogue.

36
Annex

Test your knowledge

1. Where is the Audi e-gas plant located?

□ a) Ingolstadt.

□ b) Werlte.

□ c) Wolfsburg.

□ d) Neckarsulm.

2. How do you identify an Audi A3 Sportback g-tron?

□ a) By the g-tron headlights.

□ a) By the g-tron rims.

□ c) By the g-tron logo on the seats.

□ d) By the CNG filler neck.

3. Who is authorised to carry out work on the CNG system in an Audi A3 Sportback g-tron?

□ a) Only personnel who have received instruction.

□ b) Only personnel who have received training.

□ c) Anyone.

□ d) Only the dealership.

4. How many CNG tanks are there on an Audi A3 Sportback g-tron?

□ a) 4.

□ b) 3.

□ c) 2.

□ d) 1.

5. Where is the gas pressure regulator located?

□ a) In the engine bay at the rear left.

□ b) In the engine bay at the front left.

□ c) In the engine bay at the rear right.

□ d) In the engine bay at the front right.

37
 6. For up to how long (in seconds) are injector valves N366 – N369 heated?

□ a) 30.

□ b) 60.

□ c) 90.

□ d) 120.

7. How much power does the engine in the Audi A3 Sportback g-tron develop in CNG mode?

□ a) 60 kW.

□ b) 81 kW.

□ c) 90 kW.

□ d) 122 kW.

8. What is the capacity of the CNG tanks?

□ a) Approx. 7.2 kg.

□ b) Approx. 14.4 kg.

□ c) Approx. 16.0 kg.

□ d) Approx. 27.0 kg.

9. What is the task of the "protective rubber strips"?

□ a) To protect the CNG tank from damage.

□ b) None.

□ c) To protect the CNG tank from vibration.

□ d) To prevent expansion of the CNG tank.

10. At what pressure is the CNG tank refuelled?

□ a) 5 bar.

□ b) 9 bar.

□ c) 200 bar.

□ d) 260 bar.

1 b; 2 d; 3 b; 4 c; 5 d; 6 c; 7 b; 8 b; 9 a; 10 d
Test solutions:

38
Self Study Programmes
For further information, please refer to the following Self Study Programmes.

SSP 609 Audi A3 ’13 Order number:

A12.5S00.93.20

SSP 610 Audi A3 ’13 Onboard Power Supply and Networking Order number:
A12.5S00.94.20
Information on
• Networking
• Control units

SSP 616 Audi 1.2l and 1.4l TFSI engines of the EA211 model Order number:
series A12.5S01.00.20

Information on the 1.4l TFSI engine

• Engine mechanicals
• Fuel system
• Engine management system

Information on QR codes
This SSP has been enhanced by electronic media (animations,
videos and mini-WBTs) for more effective illustration of the
content. The references on the pages to the e-media are hidden in
QR codes, which are two-dimensional pixel patterns. You can scan
those codes using a tablet or smartphone running the appropriate
app, which will decipher the hidden web address. To follow the link
you require an internet connection.
All e-media are managed on the Group Training Online (GTO)
platform. You require a user account for GTO and have to log in
after scanning the QR code before you can retrieve the media. On
an iPhone, iPad and many Android devices, you can store your login
credentials in the mobile browser. That simplifies logging in the
next time. Make sure you protect your mobile device against
unauthorised use by setting a PIN.

To read the QR codes, you need to obtain a QR scanner from the
Apple® or Google® app store and install it on your mobile device.
For some media, other players may be required in some cases.
On PCs and notebooks, the e-media can be selected in the SSP PDF
and then retrieved online after logging into GTO.
Please note that using the e-media over the mobile phone network
may incur considerable charges, especially if using data roaming
tariffs abroad. This is your responsibility alone. The best option is
to use a WiFi connection.
Apple® is a registered trademark of Apple® Inc.
Google® is a registered trademark of Google® Inc.

39
 621
Audi Vorsprung durch Technik

All rights reserved.

Technical specifications
are subject to change.

Copyright
AUDI AG
I/VK-35
service.training@audi.de

AUDI AG
D-85045 Ingolstadt
Technical status 10/13

Printed in Germany
A13.5S01.05.20