Service Training

Self-study Programme 427

The BiFuel LPG Drive

Design and Function
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 For the first time, Volkswagen is offering the Golf
2009 with the 1.6l 75kW MPI engine and LPG drive
straight from the factory. LPG is also known as liquid
gas or autogas. LPG stands for “Liquefied Petroleum
Gas”. All components that are required for gas
operation are fitted on the production line at
Volkswagen.
LPG has been in use for decades and is currently the
most popular alternative fuel across the world. It is
made from a mixture of propane, butane and
additives. It burns cleanly and is thus among the latest
of energy fuels. In many cities, more and more
vehicles are being run on LPG due to rising
environmental awareness.
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Compared with other fuels, LPG produces
considerably fewer exhaust emissions. The same
applies to carbon dioxide emissions (CO2), which are
associated with climate change. On the whole, the
exhaust emissions caused by LPG vehicles are among
the lowest that can currently be achieved with
combustion engines. LPG fuel is virtually sulphur-free
and its combustion produces almost no soot.
Hazardous substances like carbon monoxide (CO),
hydrocarbons (HC), nitrogen oxide (NOX) and other
health- and environment-harming exhaust gas
components are considerably less.

S423_889

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

LPG Drive Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

LPG System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Engine Management . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
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Functional Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Test Yourself . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

3
 Introduction

The raw material LPG

LPG (Liquefied Petroleum Gas) is a liquid gas that is Compared with petrol, LPG has a very high anti-knock
used to power combustion engines. It is just as index and, depending on the mixture ratio of propane
suitable for use as a vehicle fuel like petrol, diesel and and butane has an octane number of approx. 105 to
natural gas. 115 RON.

LPG is a waste product from natural gas and crude oil The quality requirements for LPG have been
refining. It is characterised by a high degree of purity. standardised across Europe in DIN EN 589 so one
This prevents “aging” so LPG can practically be stored will have no problems when driving abroad.
indefinitely.

The gas is liquefied under a relatively low excess

pressure of approx. 6-10bar and stored in various
types of compressed gas container. In this way, it is
possible to transport and store large quantities of fuel
in a small space. LPG can be used in any location.
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Main components
In principle, LPG is a mixture of hydrocarbons. It is
mainly made from a mixture of propane and butane.
LPG also contains an odorant. This is added as a
precaution since pure LPG is odourless and
colourless.
Propane is lighter and liquifies at lower temperatures
than butane. Butane, however, has a higher energy
proportion per volume unit. The mixing ratio is,
dependent on the market, in summer 50:50 (in
percentage propane/butane) and in winter 85:15.
Deviations from the mixing ratio are possible
depending on the supplier. Since propane delivers
less energy than butane, the consumption of LPG is
slightly higher in winter.

4
 Properties of the main components

Propane C3H8 Butane C4H10

S427_010 S427_008

Formula: CH3-CH2-CH3 Formula: CH3-CH2-CH2-CH3

Boiling point: -42.1 °C Boiling point: -0.5°C

Ignition temperature: 470°C Ignition temperature: 365°C

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(petrol 240°C) (petrol 240°C)

Properties: Properties:
- Colourless and odourless gas - Colourless and odourless gas
- Heavier than air - Heavier than air
- Extremely flammable gas - Extremely flammable gas

Use as: Use as:

- Combustion gas for heating and lighting purposes - Combustion gas in laboratories and households
- Propellant in sprays - Low-temperature solvent and extraction agent
- Balloon gas - Propellant in sprays
- Refrigerant in industry - Refrigerant in fridges
(not for freezing)

Production: Production:
Waste product from crude oil refining Waste product from crude oil refining

H = hydrogen, C = carbon

The following names for LPG are common across Europe:

- Autogas = Germany
- GPL = France “Gas de pétrole liquéfie”, also called GPL-C (GPL-carburant)
- GLP = Italy “Gas Liquido Propano”
- GLP = Spain “Gases Licuados del Petróleo” (GPL Automoción)

5
 Introduction

Advantages of LPG
Compared with conventional fuels and other alternative drive energy sources, LPG has an excellent environmental
balance as a fuel. Only hydrogen and natural gas achieve comparable results.

Customer advantages Technology and quality advantages

- After sales services from Volkswagen - Mature technology

- Full warranty for whole vehicle
- Reduction in fuel costs
- Trouble-free installation in vehicles with
petrol engines
- Constantly growing network of filling
stations, standardised fuel quality across Europe in
accordance with DIN EN 589
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- Special LPG tank
- Complete LPG system crash-tested
- Optimised exhaust gas and performance thanks to
adapted software
- Intake manifold with integrated mount for
gas fuel rail and gas injection valves
- LPG wiring harness with VW connectors

- High ranges
- Very low hazardous emissions
- Tax subsidy in Germany until 2018
- Easy switch-over from gas to petrol
(even while driving)
- Robust engine
- Filling connection behind standard filler flap and
not integrated in bumper
- Customer has added value when they sell the car

6
 Economic aspects

LPG has a higher consumption rate amounting to approx. 30 percent more when compared with premium petrol.
This is, however, balanced out by the cheaper cost. The consumption per 100 kilometres is thus approx. 7.1 litres with
petrol and 9.2 litres with LPG.

A simple example shows whether an LPG vehicle is worthwhile.

Example calculation Cost development

Euros
12,000
Annual kilometres driven 26000km

Period 5 years
9,000
Average journey distance 24km
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Cost of conversion 2500 euro

6,000
Petrol price per litre 1.26 euro

Petrol consumption per 100km 7.10 litres 3,000

LPG price per litre 0.54 euro

Autogas consumption per 100km 9.20 litres 0

0 1 2 3 4 5
Starting petrol per journey 0.10 euro S427_148 Years
LPG
Petrol

Evaluation

Annual savings compared with 365.02 euro

petrol

Depreciation distance 75,143km

Depreciation period 2.89 years

All figures given here are only examples and are dependent on the respective market.

7
 Introduction

LPG in comparison
Whenever you want to hit the accelerator in your car, you can do so with petrol, LPG or also natural gas
(abbreviation CNG = Compressed Natural Gas).
Both LPG and natural gas are sold with the claim that they are a low-pollutant alternative to conventional fuels and
drive technologies for cleaner road traffic.

Feature LPG Petrol

Composition LPG is made up of propane, butane and Petrol is a complex mixture of over 100
an odorant. different, mainly light hydrocarbons.
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Production LPG is a by-product of crude oil refining Petrol is produced in crude oil refining.
(cracking).

Filling stations LPG filling stations are easy to set up. Petrol tanks at filling stations need to be
The LPG tanks are above-ground at the built below ground at great expense.
filling station.

Cost comparison Fuel costs for LPG are lower than for Higher fuel prices for petrol and diesel
petrol. It is supplied in litres. in contrast to LPG.

Carbon dioxide (CO2) The CO2 emissions from LPG vehicles are around 15% below those from petrol
emissions vehicles.

Octane number 105–115 RON (depending on butane 91 RON for ordinary unleaded petrol
content) 95 RON for premium unleaded petrol
98 RON for super unleaded petrol

8
 Feature LPG Petrol

Life LPG is a very pure fuel and thus has Petrol has a limited life.
unlimited life.
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Boot volume The LPG tank easily fits in the spare wheel
well. As a result, you still have the full
boot volume.

Range The original petrol tank remains in the

vehicle. This allows a range of approx.
1000km.

Standard/DIN There is a European standard for LPG. The composition of petrol varies depending
DIN EN 589 regulates the quality of LPG. on the oil company.

Taxes The German government has provided a Petrol is subject to fuel tax, ecotax and VAT.
tax concession on LPG until 2018.

9
 Introduction

LPG vehicle population

The number of privately owned LPG vehicles is constantly growing. This increase shows the increasing acceptance
of LPG vehicles among the population.

In 2004, there were initially 15,000 vehicles running on LPG in Germany and just 500 public LPG stations were
available to fill them up.

Today, over 300,000 LPG-powered vehicles are on the road in Germany.

By 2015, an estimated 1.5 million LPG vehicles will be registered in Germany.
Over 5.5 million LPG vehicles are currently in use across the world.
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Development of registered LPG vehicles in Germany

1,500,000

300000
300,000

250000

200000
200,000

150000
125,000

100000
15,000

50000
65,000

S427_074
2004 2005 2006 2007 2008 2015

10
 Service station network
The LPG filling station network in Germany has grown constantly over recent years to more than 4,900 public
refuelling sites. Further LPG filling stations are planned. Therefore in Germany too — as is already the case in other
European countries — an alternative gas fuel is available in a dense network.
In most European countries (in particular in the Netherlands, France, Italy and Poland), a dense network of LPG
filling stations has been set up.

LPG filling station network in Europe as of May 2009

Belgium 529
Bosnia-Herzegovina 9
Denmark 16
Germany 4974
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Estonia 10
France 1321
Greece 22
United Kingdom 563
Ireland 98
Italy 1981
Croatia 116
Latvia 4
Lithuania 40
Luxembourg 6
Netherlands 1122
Norway 66
Austria 14
Poland 7000
Portugal 94
Rumania 34
Sweden 15
Switzerland 21
Serbia and Montenegro15
Slovenia 14
S427_066 Slovakia 8
Spain 34
Czech Republic 95
S427_064
Hungary 256

11
 LPG Drive Components

Overview of components
All components that are required for gas operation
are fitted on the production line. Normal petrol
operation remains available as usual.

The LPG system consists of:

- the gas filler neck,

- the LPG tank
- the selection button with the gas supply gauge and
the fuel selection switch
- the vaporiser
- the gas filter and
- the gas fuel rail with gas injection valves and the
gas rail sensor.
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Gas filler neck

LPG tank with

gas gauge sender G707,
pressure relief valve,
gas tank valve N495 and
automatic fill limiter

Selection button with

gas gauge G706 and
petrol or gas fuel selection switch E395

12
 Effects upon failure

If one or more components or parts in the LPG system fail, the system switches back to petrol operation. If
a fault is reported again upon restarting, the system switches to petrol mode and you should visit a
specialist workshop.

Gas mode control unit J659

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Vaporiser with
high pressure valve for
gas mode N372

Gas filter

S427_220

Gas fuel rail

with gas injection valves N366-N369
and gas rail sensor G401

13
 LPG Drive Components

1.6l 75kW engine with 2-valve technology

The basic engine is based on the FlexFuel (E85) engine with engine code CCSA, which, in turn, is based on the
technology from the 1.6l 75kW BSE engine. Both engines were used for the first time in the Golf 2004.
No mechanical modifications are required to the CCSA petrol engine for operation with LPG. Normal petrol
operation is still possible as usual and you can switch to LPG with the selection button in the centre console.
The engine reaches an output of 72kW in gas mode.

Technical features

● 2-valve roller rocker finger

● Aluminium engine block with ribbed sump
● Secondary air system
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● Plastic variable intake manifold

● Modified applications in engine control unit,
adapted to gas operation
- Gearbox code JHT as with
BSE engine
- The valve train, pistons and piston rings
from the CCSA FlexFuel engine have been
used

S427_149

This engine must not be run on ethanol (E85).

14
 Technical data Torque and power graphs compared

Engine code CHGA 200 100

Type 4-cylinder in-line engine
180 90
Displacement 1595cm3
Bore 81mm 160 80
Stroke 77.4mm
140 70
Valves per cylinder 2
120 60

Torque [Nm]
Compression ratio 10.3:1

Power [kW]
Maximum power 75kW at 5600 rpm petrol 100 50
72KW at 5600 rpm LPG
Maximum torque 148Nm at 3800 rpm petrol 80 40
144Nm at 3800 rpm LPG
60 30
Engine management Simos 7PP
Fuel Premium unleaded RON 95 40 20
(normal unleaded RON 91 with
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20 10
reduction in performance)
LPG
Exhaust Main catalytic converter 1000 3000 5000 7000
gas treatment with Lambda control Engine speed [rpm]
S427_152
Emissions standard EU4
Petrol power
Gas power
Petrol torque
Gas torque

15
 LPG Drive Components

Gas filler neck

The gas filler neck is next to the petrol filler neck
behind the tank filler flap and is connected to the LPG
tank via an LPG pipe.

S427_134
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The gas filler neck has a check valve. This allows the
liquid gas to flow in one direction and stops the liquid
gas flowing in the opposite direction.

The check valve opens when the tank is filled under

pressure.
S427_156

Pressure relief Gas filler neck Cap

valve, check valve

An adapter can be screwed onto the gas

filler neck for the different systems used in
other countries.
The gas nozzle fits onto the adapter when
you refuel.

16
 Filler neck adapter
Three different connection systems are currently in use across Europe for filling LPG vehicles. These are the “ACME
connector”, the “Dish connector” and the “Bayonet connector”. Depending on the country, you will need the right
adapter to use the LPG pumps.

ACME connector Dish connector Bayonet connector

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S427_072 S427_070 S427_068

Belgium Denmark Netherlands

Germany France
England Greece
Ireland Hungary
Luxembourg Italy
Poland Austria
Scotland Portugal
Switzerland

17
 LPG Drive Components

Refuelling procedure
A closed system is used for refuelling. Refuelling is just as simple and takes the same time as petrol. The quantity of
LPG filled is measured in litres and displayed on the delivery pump like petrol. The maximum filling capacity of the
LPG tank is just 80%, so the gas has sufficient volume to expand in summer.

After opening the fuel filler flap, you unscrew the cap
from the gas filler neck and screw on the adapter.
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S427_242

Take nozzle

S427_244

Screw nozzle to adapter and pull trigger to lock

in place.

S427_246

18
 Press start button and hold down until the tank has
been filled.
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S427_248

LPG escapes when you release the filler hose.

Keep hands away from the escape holes.
There is a risk of frostbite should gas come into
contact with skin.

S427_240

Unscrew nozzle and adapter from gas filler neck and

screw cap onto gas filler neck.

S427_250

19
 LPG Drive Components

LPG pipes
The liquid gas flows through the LPG pipes from the gas filler neck to the tank and from there to the engine. The
LPG system is divided into a high-pressure area and a low-pressure area.
The LPG pipes are made from copper piping with a PVC sleeve in the high-pressure area and from special plastic
hoses in the low-pressure area.
The following LPG pipes are fitted:

1. From gas filler neck to tank - Made from copper piping with a PVC sleeve
(high-pressure area) - Pressure from 8-10bar
- liquid LPG

2. From tank to vaporiser - Made from copper piping with a PVC sleeve
(high-pressure area) - Pressure from 8-10bar
- liquid LPG
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3. From vaporiser to gas fuel rail - Made from special plastic hosing
(low-pressure area) - Pressure from 0.1-2bar
- gaseous LPG

4. From gas fuel rail to - Made from special plastic hosing

injection valves - Pressure from 0.1-2bar
(low-pressure area) - gaseous LPG

All damaged pipes must be replaced during a repair or after an accident.

20
 LPG tank
The LPG tank is fitted in the spare wheel well. It is
made from 3.5mm thick steel.

The LPG tank with crash-optimised mounts and a swirl

pot comes with a pressure relief valve, an automatic
fill limiter, a gas gauge sender G707 and a gas tank
valve N495.

The LPG tank has a capacity of 49 litres.

The automatic fill limiter stops the refuelling process
S427_150 when there is 80% LPG in the tank. The filling level is
temperature-related and can fluctuate. At an outside
LPG tank temperature of 15°C, the LPG tank holds 39 litres.
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Pressure relief valve Automatic fill limiter

Gas gauge
sender G707 Pressure relief valve
S427_144

S427_234
Gas tank
valve N495
Gas gauge Swirl pot
sender G707
Gas tank Automatic
valve N495 fill limiter

21
 LPG Drive Components

Crash-optimised mounts

In collisions, the mounts will not break off, but instead

they will deform to absorb the crash energy.
The mounts have pre-defined deformation points for
this purpose.

S427_138

Mount Cover for

tank valve pot
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Swirl pot
Supply line from gas filler neck
There is a swirl pot in the tank. It guarantees a
Supply line to vaporiser
constant supply of gas in all driving situations, e.g. hill
start, hill descents and cornering.
Tank valve pot

The swirl pot is round and has an opening on top for

the pick-up pipe. Furthermore the swirl pot has holes
at the bottom and side to allow the liquid gas to get
inside the pot.
S427_136

The snorkel leads to the pressure relief valve in the

valve pot.

Snorkel

Swirl pot Pick-up pipe for

gas tank valve

Holes

22
 Gas tank valve N495
The gas tank valve N495 is fitted in the valve pot and
is used to interrupt the gas supply. It is a solenoid
valve and is opened by the gas mode control unit
J659 during LPG operation. The valve closes
automatically and liquid gas no longer flows to the
vaporiser when you switch over to petrol mode, turn
off the engine, are involved in an accident (crash
recognition) or when the voltage supply fails.

S427_192

How it works:
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Unpowered
The valve is pressed into the valve seat by the spring
Spring force and thus closes the access to the vaporiser.

Coil

Plunger

Valve

To vaporiser
S427_076 From tank
Powered
Spring
The gas mode control unit powers the gas tank valve
in LPG mode. The magnetic field of the coil pulls the
Coil plunger upwards against the spring force. The access
to the vaporiser is now open. If LPG mode is ended,
the gas mode control unit immediately shuts off the
gas tank valve. The valve is pushed down again by
Plunger
the spring force and the access to the vaporiser is
Valve closed.

To vaporiser

S427_078 From tank

23
 LPG Drive Components

Automatic fill limiter

The automatic fill limiter is in the valve pot of the LPG tank. It is used to stop the refuelling process. Refuelling is
stopped when the filling level of the tank reaches 80%. The automatic fill limiter is operated mechanically by a
float.

Refuelling Filling limit

Filling pressure

Upper plunger Inlet channel

Spring
Lower plunger
Spring
Outlet openings
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Lower valve chamber

Shut-off valve
S427_216
S427_218

Cam disk

Float

The filling pressure presses the upper and lower
plungers downwards. The upper plunger works as a
check valve. The lower plunger opens the outlet holes
through which liquid gas flows into the tank.
Furthermore the lower plunger has a small hole in the
centre through which the liquid gas reaches the tank
via the open shut-off valve. When the shut-off valve is
open, pressure cannot be built up in the lower valve
chamber.
Depending on the filling level, the cam disk is turned
by a float during the filling procedure. The cam disk
operates the shut-off valve.
In the float position corresponding with an 80% filling
level, the shut-off valve slips into the cam disk recess
and closes the shut-off valve. The liquid gas now
builds up pressure in the lower valve chamber.
This pressure together with the spring force causes the
lower plunger to move upwards. The side outlet holes
are then closed. The counter-pressure builds up to the
filling pressure, the filling pump switches off and the
upper plunger closes the inlet channel due to the
spring force.

24
 Pressure relief valve
The pressure relief valve is fitted in the LPG tank and is
located in the valve pot. It prevents the natural gas
tank bursting if the pressure rises excessively, for
example, because of high temperatures.
As soon as the pressure in the tank reaches 27.5bar,
the pressure relief valve opens mechanically. The LPG
first reaches the valve pot and is vented away from
the passenger compartment via breather hoses made
from plastic.

S427_228
Breather hoses Pressure
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relief valve

Pressure relief valve closed Pressure relief valve open

Dust cap Escaping LPG

Outlet aperture

Valve spring

Valve disk

Pressure in tank greater

S427_212 Pressure in tank S427_210 than 27.5bar

The valve disk is pressed downwards by the force of
the valve spring. The valve is closed. The outlet hole is
closed by a red dust cap.
If the pressure in the LPG tank is greater than the
force of the valve spring, the pressure relief valve
opens due to the valve disk being pushed upwards.
The red dust cap is pressed out and the LPG flows into
the valve pot. It is vented to atmosphere via breather
hoses.

25
 LPG Drive Components

Gas gauge sender G707

The gas gauge sender G707 is in the tank. The liquid level in the tank is shown
1. on a gauge on the tank valve pot and
2. on the fuel gauge (gas gauge G706) integrated in the selection button on the centre console.

1. Display of filling level in valve pot

Electrical connection to gas Needle

mode control unit

Float
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Top of housing Gauge

Gear mechanism

S427_236

The float for the gas gauge sender G707 moves in the LPG tank depending on the filling level. This movement is
converted into a rotary movement by the gears in the gear mechanism. This also turns the ring magnet in the top of
the housing. There is also a ring magnet in the gauge. Depending on the filling level, the two ring magnets have a
defined position in relation to each other and create a magnetic field together. This magnetic field influences the
position of the needle in the gauge from which you can then read the filling level. The filling level is only shown on
the valve pot for safety reasons.

26
 2. Display of filling level in selection button

S427_290
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Gas gauge sender G707 Gas mode control unit J659 Gas gauge G706

The driver can read the filling level from the gas gauge G706 integrated in the selection button, which is located on
the centre console in the passenger compartment. The gas gauge sender G707 in the tank needs to communicate
with the gas mode control unit J659 for this purpose.
The gas gauge sender is powered by the gas mode control unit. The magnetic field formed by the two ring magnets
then influences the electrical resistance of the conductor. Changing the electrical resistance by applying an external
magnetic field is known as a magnetoresistive effect.
Different resistances of 0-90 ohm are possible depending on the filling level in the tank. The voltage signal, which
is sent by the sender to the gas mode control unit and from there to the gas gauge in the selection button, is thus a
measurement for the filling level in the LPG tank.

27
 LPG Drive Components

Vaporiser
The LPG is converted from liquid to gaseous state in
the vaporiser.
The vaporiser also has the task of reducing the
pressure of the LPG from approx. 10bar to 1bar
above the pressure present in the intake manifold.
The LPG is expanded in the vaporiser in two stages.
The two-stage pressure reduction allows pressure
fluctuations to be better compensated for.

S427_222
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Technical features
1st stage 2nd stage
● Two-stage pressure reduction from 3-10bar to 1.6bar from 1.6bar to 1.0bar above
intake manifold pressure
● High-pressure valve for gas mode with external
connection and integrated filter element Inlet from tank
High-pressure
● Internal coolant circuit for avoiding formation of valve for gas
moisture and icing mode N372 Outlet to gas filter

S427_254
Technical data

Type Two-stage vaporiser with

diaphragm
Working pressure 0.95bar to 1.10bar
Max. working 3.5bar
pressure
Weight 1450g Vacuum connection
Operating nominal 40kg/h intake manifold
throughput Coolant, inlet Coolant, outlet
Working temperature From -20°C to 120°C

There is an inspection plug on the vaporiser. After 60,000km, this screw needs to be removed to check
the vaporiser for impurities. If impurities are found, the filter in the high-pressure valve will need to be
replaced.
Please refer to the information in ELSA and the maintenance table.

28
 Design

Each stage of the vaporiser consists of an internal chamber, an external chamber and a control chamber
containing LPG. The LPG passes from the 1st stage to the 2nd stage via the overflow channel. Also each stage has a
valve with a flap and a plunger. The plunger is bolted to the diaphragm. There is a spring in each spring chamber.
Atmospheric pressure is present in the spring chamber of the 1st stage. Intake manifold pressure is present in the
spring chamber of the 2nd stage. There is a rubber seal between the 1st and 2nd stage that separates the cooling
circuit from the LPG.

1st stage 2nd stage

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Overflow channel

Supply line from high- Outlet to gas filter

pressure valve for gas mode
Diaphragm
Diaphragm
Inner chamber
Flap

Inner chamber Flap

Plunger
Plunger
Spring
Spring

Spring chamber Spring chamber

Control chamber
Control chamber

Outer chamber Vacuum connection

intake manifold
Outer chamber

Coolant, inlet Rubber seal Coolant, outlet S427_252

29
 LPG Drive Components

Function

In gas mode, the LPG travels to the vaporiser. To illustrate the processes in the separate stages of the vaporiser, the
cross-section of the vaporiser has been greatly simplified.

1st stage

The liquid LPG passes through the high-pressure valve Supply line from high-
for gas mode with a maximum pressure of 10bar to pressure valve for gas mode

the inner chamber of the 1st stage. The valve flap is Spring chamber
open. The liquid LPG passes through the outer
chamber to the control chamber of the 1st stage. In Diaphragm
this way, the liquid LPG expands and becomes Flap
gaseous. The diaphragm of the 1st stage is influenced
by the preset spring on the spring chamber side and Spring
by the atmospheric pressure present in the spring
Control chamber
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chamber.
Inner chamber

Outer chamber
S427_270
If the gas pressure in the control chamber rises above
1.6bar, the spring will be compressed by the Overflow channel
diaphragm. The plunger bolted to the diaphragm
operates the flap and the valve closes the supply line
from the high-pressure valve for gas mode. No more
liquid gas can flow through. The LPG can continue to Flap
(closed)
expand and flow into the inner chamber of the 2nd
stage via the overflow channel.

Plunger

S427_272
If, as a result, the pressure acting on the diaphragm in
the control chamber again falls below 1.6bar, the
spring will push the flap open with the plunger and
more LPG can flow in. In this way, the pressure of the
LPG is reduced from a maximum 10bar to 1.6bar.
Flap
(open)

Spring

S427_274

30
 2nd stage:
Overflow channel
In the 2nd stage, the pressure of the LPG, which is
Spring chamber already in gaseous form, is relieved and reduced to
1bar above the intake manifold pressure. The LPG
Diaphragm
passes from the outer chamber of the 1st stage via the
Flap overflow channel to the inner chamber of the 2nd
Spring stage. The flap of the 2nd stage valve is open during
this process. When the gas expands, it passes via the
Vacuum connection outer chamber to the 2nd stage control chamber. The
intake manifold
diaphragm of the 2nd stage is influenced by the
Control chamber
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preset spring on the spring chamber side and by the

intake manifold pressure present in the spring
Inner chamber
chamber.
S427_276 Outer chamber
If the gas pressure acting on the diaphragm in the
Outlet control chamber rises 1bar above the intake manifold
pressure, the spring will be pressed together by the
diaphragm. The plunger bolted to the diaphragm
operates the flap, and the valve closes the overflow
Flap channel. No more LPG can flow through. The LPG can
(closed) continue to expand and pass through the outlet to the
filter and to the gas injection valves.

Plunger

S427_278 If, as a result, the pressure acting on the diaphragm in

the control chamber falls again to 1bar above the
intake manifold pressure, the spring will push the flap
open via the plunger and more LPG can flow in.

Flap
(open)

Spring

S427_280

31
 LPG Drive Components

Coolant circuit

Design

The coolant circuit is inside the vaporiser. The vaporiser is shown “folded open” in the middle to illustrate the design.
The coolant circuit is connected to the engine coolant system via the two coolant connections. It is split into the 1st
and 2nd stage in the vaporiser by the rubber seal. The LPG passes from the 1st stage to the 2nd stage via the two
overflow channels.

S427_262
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Overflow channel LPG

from the 1st to 2nd stage 2nd stage

1st stage
Rubber seal

S427_264
Coolant overflow
channels

Coolant, inlet Coolant, outlet

Function

When the LPG pressure is reduced from 10bar to 1bar above intake manifold pressure, the liquid LPG expands and
changes state from liquid to gas. The LPG draws thermal energy from its surroundings so the gas and its
surroundings cool down. A refrigerating effect results, which could lead to icing of the vaporiser. The vaporiser is
connected to the engine coolant system in front of the heat exchanger via the coolant connections. In this way, the
hot coolant passes through the vaporiser. This stops the vaporiser icing.

32
 High-pressure valve for gas mode N372
The high pressure valve for gas mode N372 is
mounted on the vaporiser and is used to interrupt the
gas supply to the vaporiser.
A filter is integrated into the high-pressure valve. It is
used to filter out any impurities in the liquid LPG in
order to protect the sensitive components of the
vaporiser.
This safety valve works in the same way as the gas
tank valve N495.
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The high pressure valve for gas mode N372 is a
solenoid valve and is opened by the gas mode control
unit J659 while the vehicle is running on LPG. The
valve closes automatically and liquid gas no longer
flows to the vaporiser when you switch to petrol mode,
turn off the engine, are involved in an accident (crash
recognition) or when the voltage supply fails.

Not activated Activated

Valve seat Spring Coil Valve seat Spring Coil

To vaporiser To vaporiser

Plunger Plunger
Filter Filter

From tank S427_232 From tank S427_230

The valve is pressed into the valve seat by the spring If all system requirements are met for LPG operation,
force and thus closes the access to the vaporiser. the gas mode control unit operates the high-pressure
valve for gas mode.

The magnetic field of the coil pulls the plunger against

the spring force. The access to the vaporiser is
opened. If LPG mode is ended, the gas mode control
unit immediately shuts off the high-pressure valve for
gas mode. The access to the vaporiser is closed
automatically by the spring force.
The filter in the high-pressure valve needs to
be replaced after 90,000km.

33
 LPG Drive Components

Gas filter
The gas filter is between the vaporiser and the gas
fuel rail.

It is used to protect the gas injection valves and filters

fine particles out of the gas.

S427_224
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Filter element

Gas outlet, Gas inlet,

to gas fuel rail from vaporiser

S427_132

The gas filter needs to be replaced every 30,000km.

When fitting the gas filter, make sure that the flow direction arrow corresponds with the flow direction of
the gas.

34
 Gas fuel rail
The gas fuel rail is mounted on the engine intake
manifold. Four electrically controlled gas injection
valves and a gas rail sensor G401, which measures
the pressure and temperature of the LPG, are
integrated in the gas fuel rail.

The LPG coming from the gas filter flows into the gas
fuel rail. The carefully metered gas leaves the gas
injection valves through the opening and passes
through a plastic pipe to the intake manifold.

The gas injection valves are controlled by the gas

mode control unit.
S427_226

Gas rail
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sensor G401 Gas injection valves

N366-N369

When the gas injection valves are working

in gas mode, you will hear clacking noises.
In order to counteract the greater noise in
gas mode, an insulating mat is fitted under S427_214
the bonnet.
Gas fuel rail

Gas outlet, hoses

to intake manifold Gas inlet

Electrical connection

Gas injection valve

Gas inlet

S427_172
Connection for pressure
and temperature sensor
Gas fuel rail

Gas outlet, hoses to intake manifold

35
 LPG Drive Components

Gas injection valves N366-N369

Four gas injection valves N366 - N369 are fitted on Electrical connection
the gas fuel rail.

Technical features

● Simple, robust solenoid valve

● Uses relatively large coils to prevent clogging
with LPG
● Simple fitting
● Long life (approx. 290 million cycles)
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Gas inlet

Technical data

Reaction time: 1.7ms ± 0.2 S427_142

Working temperature - 40°C to 120°C
Max. working pressure 3bar Gas outlet

Current [A]

The gas injection valves are controlled by the gas

mode control unit J659 in LPG mode with a pulse-
width modulated signal.

Actuation Time [ms]

S427_080

Before switching automatically from petrol to LPG operation, the function of the gas injection valves is
checked once each time the engine is started. This means the gas injection valves are triggered by the
control unit and opened briefly. This is a safety measure to clear residue from the gas injection valves and
prevent clogging.

36
 Function

In LPG mode, the gas injection valves deliver the gaseous LPG into the intake manifold of each cylinder.

Not activated

The gas injection valve is not powered. The pressure

spring presses the plunger with armature and sealing
Pressure lip downwards thus closing the gas outlet to the intake
spring
manifold. LPG flows into the lower chamber via the
gas inlet and into the upper chamber of the gas
injection valve via holes in the armature. As a result,
the same gas pressure acts on the armature in the
Plunger Solenoid upper and lower chamber. This prevents the armature
with sealing lip being pressed upwards against the
Upper spring force by the pressure in the lower chamber and
chamber Armature
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the gas injection valve opening the gas outlet.

Gas inlet

Lower Sealing lip

chamber
S427_258
Gas outlet

Activated

The gas injection valves are electronically

controlled by the gas mode control unit. The electrical
Pressure connection and the solenoid are located in the valve
spring
housing. The solenoid generates a magnetic field
when it is powered. The armature with sealing lip is
pulled against the force of the pressure spring.
The LPG from the upper chamber flows via the holes
Plunger Solenoid in the armature back into the lower chamber. The gas
injection valve opens the gas outlet. The LPG passes
through the intake manifold into the combustion
Armature
chamber.

Gas inlet

Lower Sealing lip

chamber

S427_260
Gas outlet

37
 LPG Drive Components

Gas fuel rail sensor G401

The gas rail sensor G401 is fitted in the gas fuel rail.

It is used to measure the pressure and temperature

of the LPG. The gas temperature and the gas pressure
are used to calculate and control the opening times of
the gas injection valves.

The gas pressure signal also determines when it is

necessary to switch back to petrol mode. Possible
reasons for this are:

- An empty LPG tank

- A pressure drop in the gas system
- A clogged gas filter
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S427_130

38
 Display in dash panel insert
The display of the average fuel consumption in the dash panel insert has been adapted to gas mode. This means
there can be discrepancies between the range reading and the fuel gauge in petrol mode.

Fuel gauge
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S427_169

S427_170

39
 LPG Drive Components

Gas gauge G706 and

petrol or gas fuel selection switch E395

The gas gauge G706 and the petrol or gas fuel

selection switch E395 are integrated in a selection
button. It is located in the centre console and controls
the following functions:

- Petrol/gas fuel selection

- Checking gas level in the tank
(fuel gauge)
- Indication of malfunctions
(flashing/acoustic signal)

S427_140
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Selection button with gas gauge G706

and petrol or gas fuel selection switch E395

Fuel selection
Selection button Petrol mode LED
You can switch over from petrol to gas (or vice versa)
with the petrol or gas fuel selection switch E395.

The fuel being used is indicated by the blue “ON” LED

for gas mode or the orange “OFF” LED for petrol
mode being constantly illuminated. If the “ON” LED
flashes quickly, this indicates that the system is waiting
to automatically switch over to gas mode during the
starting phase (which is always with petrol).
The system switches from petrol to LPG mode if the
following conditions are met: S427_050

Gas filling Gas mode LED

- Sufficient LPG in the tank
- Coolant temperature greater than 20°C
- The accelerator pedal is pressed
- Engine speed in driving mode greater than
1200 rpm.
level LEDs
Gas gauge
The row of blue LEDs shows the level of gas in the
tank. If the LPG level in the tank is very low, the red
reserve LED will be illuminated.

40
 LPG tank empty
If the LPG tank is empty, a slow continuous
acoustic signal sounds. In addition, the orange “OFF”
LED is illuminated and the blue “ON” LED flashes
slowly. The system has already automatically switched
over to petrol mode.
To switch off the acoustic signal, the driver needs to
press the selection button. Then only the orange LED
for petrol mode will be illuminated. The LPG system is
in petrol mode.
Once the gas tank has been filled again, the driver
needs to switch over to LPG mode first with the
selection button.
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Petrol mode only
You can switch between gas and petrol mode while
driving by pressing the selection button. In this case,
the orange LED will be constantly illuminated. Even
after restarting, the engine stays in petrol mode until
you press the selection button to switch to gas mode.
Malfunctions
A malfunction can have two causes:
1. A temporary fault
During a brief full-throttle manoeuvre (e.g.
overtaking), the gas pressure is no longer
sufficient due to the low filling level in the gas tank.
2. A fault in the LPG system
(e.g. a faulty gas injection valve).
In both cases, a system fault is recognised and an
entry is made in the fault memory of the gas mode
control unit.
A fast, continuous acoustic signal sounds. In addition,
the orange “OFF” LED is illuminated and the blue
“ON” LED flashes quickly.
The control unit automatically switches from gas mode
to petrol mode. To switch off the acoustic signal, the
driver needs to press the selection button. Then only
the orange LED will be illuminated. The LPG system is
in petrol mode.
1. If there is “a temporary fault”, the system switches
back to gas mode after you press the selection
button and the switch-over conditions have been
met. For example, this is when:
- the engine is running in the lower partial load
range or
- the tank has been filled again.
2. If there is “a fault in the LPG system” due to a
faulty component, it is not possible to switch over to
LPG mode.
41
 LPG System

Supply schematics

Vacuum hose to intake manifold

Coolant, outlet 9

Coolant, inlet
8
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2
7 4

1
5

Legend
1 - Gas filler neck 7 - Gas tank valve N495
2 - Adapter 8 - Vaporiser
3 - Tank 9 - High-pressure valve for gas mode N372
4 - Gas gauge sender G707 10 - Gas filter
5 - Pressure relief valve 11 - Gas fuel rail
6 - Automatic fill limiter 12 - Gas rail sensor G401

42
 13 13 13 13

12
11
10
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16

15
14 S427_112

LPG pipe approx. 10bar

LPG pipe approx. 1bar above intake manifold pressure

13 - Gas injection valves (N366-N369)
14 - Gas mode control unit J659
Vacuum hose
15 - Selection button with gas gauge G706 and
petrol or gas fuel selection switch E395
Coolant hose
16 - Intake manifold
Sensor signal cable

Actuator signal cable

43
 LPG System

Safety concept
The safety concept of the LPG system guarantees risk-free operation. The whole natural gas system is installed so
that it is protected against damage in the best possible way. All mounting points and materials are designed for
maximum safety. The high safety standard has been confirmed by a series of crash tests. The following safety
equipment and measures are provided:

1. Check valve in gas filler neck

The check valve prevents the gas flowing back while
you fill the tank up.

2. LPG tank 8
The LPG tank is located in the spare wheel well and is
thus protected against damage and the elements in 7
the best possible way. It has crash-optimised mounts
that do not break in crashes, but instead absorb the
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deformation. The tank is extremely robust and

resistant to heat. The LPG tank made from 3.5mm thick
steel meets the highest safety standards.
Each individual tank is subjected to a meticulous
5 6
check and is given a serial number by the 1
manufacturer. All LPG tanks used go through six 3
safety checks and are given a test certificate.
4

3. Automatic fill limiter in LPG tank

The automatic fill stop when the tank is 80% full
allows the LPG to expand as it becomes warm in the 2
tank. Two integrated shut-off valves prevent the gas
flowing back while you fill the tank up.

4. Pressure relief valve in LPG tank

The pressure relief valve prevents the natural gas tank
bursting if the pressure rises excessively, for example,
because of high temperatures. Pipes to the outside
stop gas getting inside the vehicle. As soon as the
pressure in the tank rises above 27.5bar, it opens
mechanically until the pressure in the tank reaches a
normal level.

44
 The odorants are added to the gas to support the high operating safety of LPG vehicles.
This allows you to detect even the smallest leaks in the LPG system with your nose.

5. Gas tank valve N495 on LPG tank

The gas tank valve N495 automatically shuts off the
gas supply when the engine is not running, in petrol
9 mode as well as in crashes.

6. High-pressure pipes
All high-pressure pipes and connecting parts are
made from copper and mainly run outside the
8 passenger compartment.
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7. High-pressure valve for gas mode N372

on vaporiser
This solenoid valve automatically shuts off the gas
supply when the engine is not running, in petrol mode
as well as in crashes.

8. Low-pressure pipes
Flexible gas pipes on the low-pressure side prevent
damage caused by vibrations.

9. Gas injection valves

The valves only open when they are operated by the
gas mode control unit J659.

S427_238

45
 System Overview

Sensors
G707 Gas gauge sender

E395 Petrol or gas fuel selection switch

G401 Gas rail sensor

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G62 Coolant temperature sender

J659 Gas mode control unit

G28 Engine speed sender

G71 Intake manifold pressure sender

46
 Actuators

N495 Gas tank valve

G706 Gas gauge

N372 High-pressure valve for gas mode

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N366 Gas injection valve 1

N367 Gas injection valve 2
N368 Gas injection valve 3
N369 Gas injection valve 4

N30 Injector, cylinder 1

N31 Injector, cylinder 2
N32 Injector, cylinder 3
N33 Injector, cylinder 4

S427_190

47
 Engine Management

Control units
In addition to the engine control unit J623, the gas mode control unit J659 is required to control the gas mode.
There is a connector on the engine wiring harness running to the petrol injectors. The petrol injection signals are
interrupted there and forwarded to the gas mode control unit. There the signal is used to calculate the gas injection
times. To avoid a fault entry in the engine control unit, the engine control unit receives the expected petrol injector
signals via resistors in the gas mode control unit.

Gas mode control unit J659

Engine control unit J623 Gas mode
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Connector on wiring
Wires harness
disconnected

Colour code/legend

= earth
= positive
S427_282
Petrol injector Gas injection valve

48
 Gas mode control unit J659
A microprocessor in the gas mode control unit J659 takes over gas regulation to ensure low-emissions and the most
efficient combustion in the engine.

Engine control unit J623 Gas mode control unit J659

Colour code/legend

= input signal
= output signal
= earth
S427_176 = positive
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Engine sensors: Gas sensors, actuators:

● Coolant temperature ● Gas gauge sender
sender ● Gas gauge G706
● Engine speed sender ● Petrol or gas fuel selection switch
● Intake manifold pressure E395
sender ● Gas rail sensor
● Gas tank valve
● High-pressure valve for gas mode
● Gas injection valves

Engine control unit J623

The starting application in engine control unit J623 has been adapted to ensure safe restarting of the vehicle even
after the vehicle has been parked in LPG mode.

49
 Functional Diagram

Terminal 30
Terminal 15

J299

S S S S S

A K

G28 G185 G79 G42 G71

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V101 F

G476

J623

G61 G186 G187 G188 J338 G130 G39 G40

G83

S427_200

A Battery G187 Throttle valve drive angle sender 1 for electric

E395 Petrol or gas fuel selection switch throttle
F Brake light switch G188 Throttle valve drive angle sender 2 for electric
G6 Fuel system pressurisation pump throttle
G28 Engine speed sender G401 Gas rail sensor
G39 Lambda probe G476 Clutch position sender
G40 Hall sender G706 Gas gauge
G42 Intake air temperature sender G707 Gas gauge sender
G61 Knock sensor 1 J17 Fuel pump relay
G62 Coolant temperature sender J299 Secondary air pump relay
G71 Intake manifold pressure sender J329 Terminal 15 voltage supply relay
G79 Accelerator position sender J338 Throttle valve module
G83 Radiator outlet coolant temperature sender J519 Onboard supply control unit
G130 Lambda probe after catalytic converter J623 Engine control unit
G185 Accelerator position sender 2 J659 Gas mode control unit
G186 Throttle valve drive for electric
throttle

50
 Terminal 30
Terminal 15

J329 J519

J17

N372 N495 G401

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G6 N30 N31 N32 N33

J623 J659

K
E395 G706 G707
G62
N366 N367 N368 N369

N30 Injector, cylinder 1 Colour code/legend

N31 Injector, cylinder 2
= input signal
N32 Injector, cylinder 3
N33 Injector, cylinder 4 = output signal
N366 Gas injection valve 1 = positive
N367 Gas injection valve 2
= earth
N368 Gas injection valve 3
N369 Gas injection valve 4 = powertrain CAN data bus
N372 High-pressure valve for gas mode
N495 Gas tank valve
V101 Secondary air pump motor

K Diagnostic connection
S Fuse

1 CAN data bus

2 CAN data bus

51
 Service

A pressurised gas tank check is carried out after 10 years as part of the normal MOT. An appropriate test decides
whether the LPG tank needs to be replaced.

The gas filter needs to be replaced every 30,000km.

The paper filter in the high-pressure valve for gas mode in the vaporiser needs to be replaced every 90,000km.

The vaporiser needs to be checked for impurities every 60,000km. The inspection bolt on the vaporiser should be
removed for this purpose. If impurities are found, the filter in the high-pressure valve will need to be replaced.
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Please refer to the service information in ELSA!

Perform a gas system test after any repair work is performed on the gas system
(see “Maintenance Manual; book 26.1.”)

52
 Special tools

Description Tool Application

VAS 6227 For finding leaks in LPG system
Gas leak detector for components
natural gas vehicles

S427_119

BiFuel software Diagnosis software for gas mode control unit

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to read and clear fault memory.

S427_284

USB diagnosis cable For connecting gas mode control unit to the
corresponding diagnosis device
(VAS 5051B, notebook).

S427_286

53
 Service

Parking in underground car parks (Germany)

LPG vehicles are allowed to park in underground car parks. The German garage regulations have taken the high
level of safety technology used with LPG into account and allow LPG vehicles full access. All German states have
now used this common building regulation as a basis for their local laws.

Safety in accidents
The risk of an uncontrollable LPG leak in an accident is extremely small because several safety features would have
to fail at the same time. Crash and fire tests have shown that vehicles powered by LPG are no more dangerous than
petrol vehicles.
If a gas leak is discovered at the accident scene (e.g. there is a smell of gas), the following measures should be
taken:
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● Switch off engine

● Switch off ignition
● Clear and cordon off the danger area
● Do not start the vehicle. If it has to be removed from an enclosed space, push it.
● Ventilate the vehicle interior (open doors, windows, bonnet and boot)
● Establish where the gas is concentrated, remember it will collect in areas close to the ground
● Ensure adequate ventilation, “blow away” LPG with fan
● Avoid ignition sources

If the vehicle should catch fire and the LPG tank also be exposed to heat, there is no risk of the tank exploding. At a
pressure of approx. 27.5bar inside the tank, the pressure relief valve opens and the LPG is released in a controlled
manner. The gas released from the safety valve ignites and burns off in a controlled manner.

If there is a smell of gas, you should not disconnect the battery in case sparks ignite the gas.

54
 Test Yourself

Which answers are correct?

One or several of the answers could be correct.

1. What is the decisive difference between natural gas and LPG?

a) LPG is basically a propane and butane mixture.

b) LPG is stored in the tank at 200bar.

c) LPG and natural gas are made from what is known as camping gas.

2. In which vehicles is Volkswagen using LPG?

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a) Polo model year 2009.

b) Golf model year 2009.

c) Passat EcoFuel.

3. Autogas is another term for?

a) CNG “Compressed Natural Gas”.

b) LPG “Liquefied Petroleum Gas”.

c) LPG “Little Pressure Gas”

4. Using LPG has benefits for …

a) the engine

b) the environment

c) the vehicle owner

55
 Test Yourself

5. What is the boiling point of propane?

a) - 5°

b) - 32°

c) - 42°

6. Which statement is correct?

a) The LPG tank is designed as an underfloor tank.

b) The LPG tank replaces the petrol tank.

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c) The LPG tank is fitted in the spare wheel well.

7. At what pressure is LPG stored in the tank?

a) Between 20 and 25bar depending on the outside temperature.

b) At up to 10bar.

c) At the same pressure as natural gas vehicles

8. At what coolant temperature does the engine switch to LPG?

a) 30°

b) 25°

c) 20°

56
 9. In the Golf BiFuel, the engine always starts

a) with LPG.

b) with a mixture of LPG and petrol.

c) with petrol.

10. How is a fault in the gas system indicated?

a) In the selection button, the orange LED flashes quickly, the blue LED is constantly illuminated and a fast
intermittent acoustic signal sounds.

b) In the selection button, the blue LED flashes quickly, the orange LED is constantly illuminated and a fast
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intermittent acoustic signal sounds.

c) In the selection button, the orange LED flashes quickly, the blue LED is constantly illuminated and a
constant acoustic signal sounds.

11. After how many kilometres does the gas filter need to be replaced?

a) After one year and 15,000km

b) After 90,000km

c) After 30,000km without time limit

1. a); 2. b); 3. b); 4. a), b), c); 5 c); 6 c); 7 b); 8 c); 9 c); 10 b); 11 c)
Answers

57
 ProCarManuals.com

58
Notes
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59
 427
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© VOLKSWAGEN AG, Wolfsburg

All rights and rights to make technical alterations reserved.
000.2812.21.20 Technical status 06.2009

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

❀ This paper was manufactured from pulp that was bleached without the use of chlorine.