Part12 PDF

Service
Workshop Manual Volksw

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Gas drive - General information, commercial vehicles
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Service Department. Technical Information

Service
List of Workshop Manual Repair Groups
Repair Group
00 - Technical data
20 - Fuel supply system
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Technical information should always be available to the foremen and mechanics, because their
Prote AG.
careful and constant adherence to the instructions is essential to ensure vehicle road-worthiness and
safety. In addition, the normal basic safety precautions for working on motor vehicles must, as a
matter of course, be observed.
All rights reserved.

No reproduction without prior agreement from publisher.
Copyright © 2018 Volkswagen AG, Wolfsburg D4B80860AD6

Caddy 2004 ➤ , Caddy 2011 ➤ , Caddy 2016 ➤
Gas drive - General information, commercial vehicles - Edition 06.2018
Contents
00 - Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1 Safety information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Safety precautions when working on natural gas system . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 General notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.1 General reference material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 Induction training/staff qualifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 Induction training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 Accepting vehicles with natural gas system for repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.1 Accepting vehicle for repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5 Legal texts and specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.1 Regulations and directives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
5.2 Workplace requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
6 Basic technical and physical properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
6.1 Physical data of dried natural gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
7 Repair instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
7.1 Rules for cleanliness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
8 Checking gas system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
8.1 Test prerequisites for gas systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
8.2 Checking gas system for leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
8.3 Searching for leaks in gas system using gas leak detector . . . . . . . . . . . . . . . . . . . . . . . . 9
8.4 Searching for leaks in gas system using leak detector spray . . . . . . . . . . . . . . . . . . . . . . . . 11
9 Distinguishing between pressure sections of natural gas supply system . . . . . . . . . . . . . . 12
9.1 High-pressure section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
9.2 Low-pressure section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
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20 - Fuel supply system . . . . . . . .o.lks.w.ag.e.n A. G. . . . . . . n.A.G.do.e.s n.o . . . . . . . . . . . . . . . . . . . . . 13
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1 Fuel . . . . . . . . . . . . . . s.ed. b.y. . . . . . . . . . . . . . . . . . . . . . . . . .u.ar.an. . . . . . . . . . . . . . . . . . . . . 13
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1.1 Handling natural gasutfuel ho tanks . . . . . . . . . . . . . . . . . . . . . . . . . . .e o. . . . . . . . . . . . . . . . . . .
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1.2 Storing natural gasss tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . c. . . . . . . . . . . . . . . . . 13
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1.3 Damage assessment catalogue for steel fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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1.4 General information on emptying natural gas fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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1.5 Rendering natural gas tanks insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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1.6 Disposing of natural gas fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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2 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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2.1 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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ii Contents
00 – Technical data
1 Safety information
(VRL011641; Edition 06.2018)
⇒ “1.1 Safety precautions when working on natural gas system”,
page 1
1.1 Safety precautions when working on natural gas system

Risk of freezing injury from escaping natural gas
Natural gas could escape in an uncontrolled manner from the
high-pressure area of the natural gas system.
There is a risk of injury on hands and other parts of the body due
to freezing.
– Before working on the natural gas system in the high-pressure
area, allow the pressure to drop.
Risk of fatal injury and explosion from escaping natural gas

Risk of fatal injury and explosion from static discharge and sour‐
ces of ignition near natural gas systems. Escaping natural gas
may ignite and cause an explosion.
Severe or fatal injury from explosion.
– Wear safety clothing with a cotton content of at least 35%.
– Wear safety gloves with a cotton content of at least 35%.
– Wear safety shoes.
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1. Safety information 1
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⇒ “2.1 General reference material”, page 2
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♦ Self-study Programme No. 262 (Natural gas - An alternative
spec
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♦ Self-study Programme No. 373 (Natural gas drive EcoFuel in
the Caddy)
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2 Rep. gr.00 - Technical data

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Induction training/staff qualifications
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⇒ “3.1 Induction training”, page 3
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Anyone employed in a workshop who comes into contact with
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gas-powered vehicles must receive adequate and suitable induc‐
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The induction training must be repeated on an annual basis at
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Why is induction training necessary?

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to meet their duty of care obligations.
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Scope of induction training

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repairs/activities on the vehicle if I have received induction train‐
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How do I identify a leaking vehicle?
What action do I take in the event of a leaking vehicle?
Which safety regulations must be observed, e.g. avoiding sources
of ignition or covering components.
How do I mark a leaking vehicle?
How can I make a leaking vehicle safe, e.g. by closing the tank
valve with the handwheel?
What training do I need to complete that qualifies me to work on
components that have gas in them?
What does controlled release of gas and uncontrolled release of
gas mean?
♦ A controlled release of gas on a repaired and closed natural
gas system means using the handwheel to open the shut-off
valve on the fuel tank briefly and close it again in order to sub‐
sequently perform a leakage test. In this case, the maximum
amount of gas in the line could escape if the natural gas sys‐
tem is leaking. This activity may be performed in the gas
vehicle work area.
♦ An uncontrolled release of gas means that gas is escaping
from the fuel tank despite the handwheel being closed or the
ignition being switched off. In this case, the vehicle must not
be brought into the workshop under any circumstances. The
vehicle must be left where it stands and the area around it
(10x10 metres) cordoned off and marked.
Induction training must be updated when required, e.g. if new ve‐
hicle technology or new legislation is introduced.
3. Induction training/staff qualifications 3

Note
In all cases, the country-specific requirements must be observed!
For any type of work on a gas-powered vehicle, the information

in ELSA and the Offboard Diagnostic Information System (ODIS)
must be observed and heeded.
Who is permitted to deliver induction training?
Any person in a dealership who is qualified to work on a gas sys‐
tem is permitted to deliver induction training to the rest of the
workforce.
Documentation of induction training
A written record must be kept in the documentation on which in‐
duction training was provided to whom and when. The induction
training documentation must be managed by the superior respon‐
sible.
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4 Accepting vehicles with natural gas

system for repairs
⇒ “4.1 Accepting vehicle for repairs”, page 5
4.1 Accepting vehicle for repairs

A reliable way to identify whether a vehicle has a gas system is
to look for the additional filler neck behind the tank flap.
When taking delivery of gas-powered vehicles, a check must be
carried out to determine whether there are any signs of a leaking
gas system.
If there are signs of a leaking gas system, additional measures
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If the leak can be stoppedthby
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out in the gas work area. If the leakage cannot be stopped, the
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If there are no signs of a leaking system and no work needs to be
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carried out on the gas system, the vehicle can be repaired/serv‐
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4. Accepting vehicles with natural gas system for repairs 5

5 Legal texts and specifications

⇒ “5.1 Regulations and directives ”, page 6
⇒ “5.2 Workplace requirements”, page 6
5.1 Regulations and directives

Country-specific legislation, rules and regulations apply for work‐
ing with natural gas as well as on or around natural gas systems.
In Germany, for example, TRG, TRGS and TRBS apply among
others.
5.2 Workplace requirements

A work area for gas-powered vehicles with sufficient ventilation
by natural or mechanical means is one in which an air exchange
of at least 3 times per hour is assured for the period of controlled
gas release.
For natural workplace ventilation, it is recommended to locate it
in the vicinity of doors, windows and/or skylights.
It is recommended to install a gas detector in the work area for
gas-powered vehicles. By installing a gas detector on the ceiling,
assurance is provided that a warning is given before the lower
explosion threshold is reached.
In all cases, the country-specific requirements AGmust
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6 Basic technical and physical proper‐

ties
⇒ “6.1 Physical data of dried natural gas”, page 7
6.1 Physical data of dried natural gas
Note
Dried natural gas does not create methane hydrates. Methane

hydrates can cause deposits to form in the components.
Chemical formula CH4

Methane content 79-99%
Characteristics Colourless
Odour Odourless but could have odor‐
ant (odorous substance) added
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Boiling point at 1 bar -161°C agen oes
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Ignition temperature approx. 575°C to 625°C ised ara
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Ignition threshold Lower explosion aut threshold
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Relative density (air = 1) 0.55 to 0.75 (lighter than air)
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RON 130-140
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Energy content 1 kg: approx. 13.5 kWh
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Colour Natural gas is invisible
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Effects on metal Contamination of the gas can
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corrode certain metals and
plastics. This can lead to block‐
age, leaks or deposits on
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springs and valves.
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Water content Only very small amounts of wa‐

ter are soluble in liquid gas.
Flammability Natural gas is an extremely in‐
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air mixtures forming during use.

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6. Basic technical and physical properties 7

7 Repair instructions
⇒ “7.1 Rules for cleanliness”, page 8
7.1 Rules for cleanliness

When working on the fuel supply and injection system, pay careful
attention to the following rules:
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♦ Thoroughly clean all connectionsVol and adjacent areas before ot gu
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♦ Place removed parts on au a clean surface and cover them over.
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♦ Carefully cover opened components or seal them if repairs
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♦ Install clean components only. Do not remove replacement
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♦ If system is open, do not work with compressed air.
♦ Do not move the vehicle.
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♦ Immediately seal open lines and unions with clean plugs, for
example from engine bung set - VAS 6122- .
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♦ Protect disconnected electrical connectors from dirt and water,
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8 Checking gas system
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⇒ “8.1 Test prerequisites for gas systems”, page 9
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⇒ “8.2 Checking gas system for leaks”, page 9
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⇒ “8.3 Searching for leaks in gas system using gas leak detector”,
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⇒ “8.4 Searching for leaks in gas system using leak detector
spray”, page 11
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8.1 Test prerequisites for gas systems
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Special tools and workshop equipment required
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• The fuel tanks must be pressurised to at least 160 bar.
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• The self-diagnosis of the gas system using the ⇒ Vehicle di‐
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8.2 Checking gas system for leaks
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Note
♦ Different processes are described in this workshop manual for

leak detection in the gas system. These processes have been
tested. They lead to a positive result under the different con‐
ditions of use if the application is carried out correctly and in
accordance with the complaint.
♦ Small leaks can be detected e.g. with an electronic leak de‐
tector or leak detector spray.
♦ A wide range of processes are offered on the open market for
finding leaks in gas systems. These processes do not always
produce conclusive results. It is even possible for components
of the gas system to be identified as leaking even though they
are not. Furthermore, certain processes can cause preliminary
or permanent damage to the components of the gas system.
♦ Components that are found to be leaking must not be repaired.
♦ A leaking gas system must not be charged with gas.
8.3 Searching for leaks in gas system using

gas leak detector
Special tools and workshop equipment required
8. Checking gas system 9

♦ Gas leak detecting system - VAS 523 003-
Prerequisites for testing

• All parts of the natural gas system to be checked must be
easily accessible.
• The exhaust emissions warning lamp in the dash panel insert
must not light up.
• There must not be any gas-relevant entries in the event mem‐
ory of the engine control unit
• Every draught of air above 1.8 km/h (slight gust of wind) will
result in falsification of the measuring result. Therefore, it is
essential to work in a draught-free environment.
Note
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♦ With the gas leak detector - VAS 523 y V 003- it is only possible
olks ot g
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to determine whether gas is presentir se
d b
in the air immediately ran
surrounding the area being tested.o tee
th or
au ac
s
♦ If the green LED does not light up, the leak detector spray must
s
ce
le
be used as a definitive means of testing the area. No bubbles

un
pt
an
d
may form in the sprayed area during the 3 minute testing time.
itte
y li
erm
ab
ility
ot p
DANGER
wit
is n
h re
ole,
Risk of explosion and danger to life due to sources of ignition in

spec
the vicinity of the natural gas system. Escaping natural gas may
t to the co
ignite and cause an explosion. Severe or fatal injury from ex‐

plosion.
– Always make sure there are no possible sources of ignition
rrectne
close to the natural gas system.

ss o
DANGER
cial p
f inform
Risk of explosion and danger to life due to escaping natural gas.

mer
Leaks in natural gas system may lead to uncontrolled escape

atio
m
of natural gas. Severe or fatal injury from explosion.

o
n
c
i
or
n thi
– Check natural gas system for leaks.

te
sd
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o
pr
cum
r
fo
en
ng
t.
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Cop py
t. rig
gh ht
pyri by
Vo
co lksw
by
cted agen
Prote AG.

DANGER
A hissing noise is a sign that there are leaks in the natural gas
system. Leaks in natural gas system may lead to uncontrolled
escape of natural gas.
– Do not perform any kind of work on the natural gas system
if leaking gas can be heard.
– If a gas leak can be heard, do not drive the vehicle into the
AG. Volkswagen AG d
workshop. kswagen oes
not
Vol gu
– Park the vehicle outside and cordonsed by off the area around it. ara
n ri tee
ho
aut or
ac
Leak detection ss
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nl
pt
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– Start the leak detector according to the operating instructions.
an
itte
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erm
– Always hold the test probe at several points for 5 seconds re‐
ab
ility
spectively above the area of the suspected leak.
ot p
wit
, is n
If the frequency of the acoustic signal increases (design feature),
h re
hole
a warning sounds or the LEDs light up, the leakage has been
spec
localised. In this case, refer to the owner's manual supplied with
es, in part or in w
t to the co
the leak detector.
8.4 Searching for leaks in gas system using
rrectness of i
leak detector spray
l purpos
Sequence of operations
nform
ercia
DANGER
m
at
om
io
n
c
in t
or

his
ate
plosion.
do
priv
cum

for
en
g

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t.
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Cop py
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Vo
DANGER
o
by c lksw
cted agen
Prote AG.
DANGER
workshop.
– Park the vehicle outside and cordon off the area around it.
– Spray the leak detector spray all around the connections, and
observe the area for several minutes.
If small bubbles form, the leakage has been localised.
8. Checking gas system 11

9 Distinguishing between pressure

sections of natural gas supply system
⇒ “9.1 High-pressure section”, page 12
⇒ “9.2 Low-pressure section”, page 12
9.1 High-pressure section

Description
• The pressure sections are defined by the components of the
natural gas system.
• The pressure system comprises the high-pressure section and
the low-pressure section.
Note
The high-pressure section includes all gas-conducting compo‐

nents from the filler neck up to and including the pressure regu‐
lator.
♦ Natural gas fuel tank

♦ Tank shut-off valves with solenoid valves
♦ High-pressure lines
♦ T-piece
♦ Filling connection with filler line
♦ Pressure regulator (transition between high-pressure and low-
pressure sections) agen
AG. Volkswagen AG d
o
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Vol ot g
9.2 Low-pressure section ris
ed by ua
ran
tee
tho or
Description au ac
ss
ce
e
• The pressure sections are defined by the components of the

nl
pt
du
natural gas system.

an
itte
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erm
ab
• The pressure system comprises the high-pressure section and

ility
ot p
the low-pressure section.

wit
, is n
h re
hole
spec
Note
es, in part or in w
t to the co
The low-pressure section comprises all gas-conducting compo‐

nents from the pressure regulator up to and including the gas
rrectness of i
injection valves.
l purpos
♦ High-pressure line
♦ Pressure regulator (transition between high-pressure and low-
nf
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pressure sections)
rm
m
atio
m
♦ Low-pressure line
o
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or c
♦ Gas rail with gas injection valves and pressure and tempera‐
thi
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a
ture sender
iv
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o
♦ Intake manifold
f
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Cop py
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Prote AG.

20 – Fuel supply system

1 Fuel
⇒ “1.1 Handling natural gas fuel tanks”, page 13
⇒ “1.2 Storing natural gas tanks ”, page 13
⇒ “1.3 Damage assessment catalogue for steel fuel tanks”, page
15
⇒ “1.4 General information on emptying natural gas fuel tanks”,
page 15
⇒ “1.5 Rendering natural gas tanks insert”, page 17
⇒ “1.6 Disposing of natural gas fuel tanks ”, page 18
1.1 Handling natural gas fuel tanks

• Secure tanks against falling over.
• Lay down unsecured cylinders, and take measures to prevent
them from rolling away.
• Tanks must never be thrown.
• Shield tanks against thermal radiation aboveo60°C.
lksw
age es n
ot g
byV ua
If they should fall, the tanks may become rseverely
ise
d deformed and ran
tee
break open. The pressure and also considerable
utho force are re‐ or
leased rapidly in the process. Flying sfragments
s a
of cylinders can ac
cause severe injuries.
ce
e
nl
pt
du
an
Valves may break off if cylinders are not properly transported. To
itte
y li
erm
protect cylinder valves, cylinders are only to be transported with
ab
ility
appropriate tensioning straps.
ot p
wit
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1.2 Storing natural gas tanks
h re
hole
spec
es, in part or in w
Where should they be stored?
t to the co
Charged natural gas fuel tanks may only be stored in well venti‐
lated areas that have restricted access. Storing in the open, e.g.
in a wire cage is ideal for this purpose. The gas must be able to
rrectness of i
dissipate upwards without restriction.

l purpos
Should it be necessary in exceptional circumstances to store

them in a building, the area is to be engineered in such a way that
nf
ercia
no explosive atmosphere can develop at any time.

orm
m
atio
How should they be stored?

om
n in
c
When removed, natural gas fuel tanks are to be secured to pre‐

or
thi
e
vent them from falling over or down. Through the type of storage,
t
sd
iva
assurance must be provided that no damage can be caused to

o
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cu
the fuel tank.

o
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f
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Marking of storage area Cop py
t. rig
gh ht
yri
The wire cage should not be located in an area in which temper‐ p by
co Vo
lksw
atures in excess of 60°C are experienced in the shade.
by
cted agen
Prote AG.
1. Fuel 13
Caddy 2004 ➤ , CaddyA2011 olk➤
swa,gCaddy
en AG 2016 ➤
en G. V
Gas drive - General
olkswaginformation, commercial
does vehicles - Edition 06.2018
no
V t gu
by ara
ed nte
The storage areaho (e.g. wire
ris
cage) is to be marked as follows: eo
aut ra
GHS pictogram
ss Flame c
ce
e
nl
pt
du
an
itte
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erm
ab
ility
ot p
wit
, is n
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spec
es, in part or in w
t to the co
rrectness of i
GHS pictogram Natural Gas Fuel Tank
l purpos
With the following safety notices:
nform
ercia
♦ F+: R12
m
at
♦ Highly inflammable
om
ion
c
in t
♦ Compressed gas
or
his
ate
♦ Can cause suffocation in higher concentrations.
do
priv
cum
for
en
ng
t.
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op
Note C py
t. rig
gh ht
pyri by
Vo
♦ If natural gas fuel tanks have to be stored for extended periods
co lksw
by
cted agen
of time, they should be emptied and rendered inert (flushed Prote AG.
with nitrogen).
♦ In the event of a fire, charged fuel tanks are especially haz‐
ardous. For this reason, they must either be removed from the
fire area or sprayed with water. The fire brigade is to be in‐
formed in any case about the presence of natural gas fuel
tanks.
♦ In Germany, the following applies:
♦ Charged and gas-tight natural gas fuel tanks that are removed
from a vehicle and are installed back in the vehicle on the same
day (within 8 hours), may be kept alongside the vehicle during
this period.
♦ When removed, natural gas fuel tanks are to be secured to
prevent them from falling over or down.
♦ Through the type of storage, assurance must be provided that
no damage can be caused to the fuel tank.
Marking of natural gas fuel tanks

Removed fuel tanks that have not been rendered inert are to be
clearly marked (e.g. with a hanging sign) as follows:
♦ Fuel tank (natural gas/CNG)
♦ Fill level of fuel tank
♦ Vehicle code or vehicle identification number
14 Rep. gr.20 - Fuel supply system

1.3 Damage assessment catalogue for steel

fuel tanks
Procedure for the assessment in the event of accidental damage
Note
♦ Observe country-specific specifications.

♦ As long as the fundamental structure of the vehicle (e.g. lon‐
gitudinal members) is intact, the gas system/fuel tank should agen
AG. Volkswagen AG d
oes
be inspected in accordance with the damage assessment y Volksw not
gu
catalogue, and visual checks of the natural gas fuel tank ise dfor
b ara
nte
corrosion and leak-tightness should be carried out. If tthe
hor result eo
is OK, no components of the gas system will need s ato
u
be re‐ ra
c
newed. s
ce
e
nl
pt
du
♦ Thermal influences could have a negative influence on the
an
itte
y li
structure of the fuel tank.
erm
ab
ility
ot p
wit
• If the vehicle structure (e.g. longitudinal members) is dam‐
, is n
h re
aged, the fuel tanks must be removed, inspected and/or re‐
hole
spec
newed as necessary.
es, in part or in w
t to the co
• If it is found that the structural elements of the gas system are
deformed, the fuel tank must always be replaced.
• If the stainless steel lines are bent or damaged, the relevant
rrectness of i
components must be renewed.
l purpos
• The fuel tank must be renewed even if it exhibits the smallest

amount of damage or rust. No repair measures may be carried
nform
ercia
out on the fuel tank.

m
• There must be a layer of wax between the fuel tank (steel) and
at
om
io
tank shut-off valve to protect against corrosion.
n
c
in t
or
his
e
1.4 General information on emptying natural gas fuel tanks

at
do
priv
cum
or
Marking of drainage area

f
en
ng
t.
yi Co
Cop py
ht. rig
rig ht
py by
co Vo
by lksw
cted agen
Prote AG.
1. Fuel 15
AG. Volkswagen AG d
agen oes
olksw not
y V gu
d b ara
ise nte
Caddy 2004th➤ o , Caddy 2011 ➤ , Caddy 2016 ➤
r eo
u ra
Gas drivess-a General information, commercial vehicles - Edition c 06.2018
ce
e
nl
pt
du
- Marking of explosive areas
an
itte
y li
and spaces
erm
ab
ility
ot p
- Natural gas fuel tank
wit
, is n
h re
- Unauthorised access to ex‐
hole
plosive areas must be preven‐
spec
ted
es, in part or in w
t to the co
- Prohibition sign: Mobile
phones prohibited
rrectness of i
- Prohibition sign: Fire, naked
lights and smoking prohibited
l purpos
- Prohibition sign: Smoking

prohibited
nf
ercia
orm
m
atio
om
n in
or c
thi
te
sd
iva
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o
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f
en
ng
t.
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Cop py
t. rig
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pyri by
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co lksw
by
cted agen
Prote AG.
Basic conditions for releasing natural gas from natural gas fuel
tank
♦ Outside temperature between -10 to 40°C
♦ Wind speed less than 15 m/s
♦ No stormy weather expected.
DANGER
Risk of fatal injury and explosion from sources of ignition and
static discharge.
– Never empty natural gas fuel tanks in enclosed spaces.
– Never empty natural gas fuel tanks in stormy weather.
– Cordon off an area of 10x10 m.
– Permanently man the cordoned off area.
– Never bring sources of ignition into the cordoned off area.

DANGER
Risk of explosion and danger agen to life due to sources
AG. Volkswagen AG does of ignition in
olksw gas system. Escaping
the vicinity of the ynatural natural
not gas may
V gua
ignite and cause
ris
ed b an explosion. Severe or fatal injury rfrom
ante ex‐
plosion. utho eo
ra
a
– Alwaysss make sure there are no possible sources of ignition c
ce
le

un
pt
an
d
itte
y li
rm
ab
pe
DANGER
ility
ot
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
DANGER
l purpos

nform
ercia

m
a
com
tion in
r
te o
if leaking gas can be heard. thi

s
iva
do
r
rp
cum
fo
workshop.
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c
Before releasing the natural gas, the following precautions must
lksw
cted agen
Prote
be taken against static discharge:
AG.
♦ Workwear or safety clothing should not be changed in the work

area (no dressing and undressing).
♦ The mechanic must wear electrically conductive shoes and
gloves.
♦ Before fitting the gas extractor - VAS 523 001A- , establish
equipotential bonding between the mechanic and the natural
gas fuel tank.
The drain opening must be at least 3 metres above ground level.
Cordon off an area around the drain opening with a radius of 5
metres. Within the security area, there must be:
♦ no buildings
♦ no activated mobile telephones
♦ no effective sources of ignition (e.g. naked flames, hot surfa‐
ces or statically charged objects)
♦ and no unauthorised persons.
Measures should be taken to ensure that no gas can make its way
under shelters/shelves, in adjacent buildings, through open win‐
dows, doors or other openings.
Drain fuel tank ⇒ Rep. gr. 20 ; Fuel tank; Draining fuel tank .
1.5 Rendering natural gas tanks insert

Since gas is released when rendering a tank inert or filling with
water, this must be done outside only.
1. Fuel 17
DANGER
Risk of fatal injury and explosion from sources of ignition and
static discharge.
– Never empty natural gas fuel tanks in enclosed spaces.
– Never empty natural gas fuel tanks in stormy weather.
– Cordon off an area of 10x10 m.
– Permanently man the cordoned off area.
– Never bring sources of ignition into the cordoned off area.
DANGER
plosion.
DANGER
swage es n
DANGER byV
olk ot g
ua
d ran
ir se
Risk of explosion and danger to life due to escaping natural tho gas. tee
or
A hissing noise is a sign that there are leaks in the natural
au gas ac
ss
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
workshop.
es, in part or in w
t to the co
With water
rrectness of i
– Stand the fuel tank up so that it is vertical and fill to the brim
l purpos
with water, ensuring that no pockets of gas form in the fuel

tank. Leave the fuel tank to stand for 24 hours.
nform
ercia
With nitrogen
m
at
– Position fuel tank vertically. Insert a hose or a lance in the fuel

om
ion
tank opening until it reaches the bottom. Then fill the fuel tank
c
in t
or
with nitrogen. In this way, any gas is forced to the top and out
his
ate
through the fuel tank opening.

do
priv
cum
or
1.6 Disposing of natural gas fuel tanks

f
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
• Before natural gas fuel tanks are transported and disposed of,
c by lksw
cted agen
they must be completely emptied ⇒ Rep. gr. 20 ; Fuel tank;
Prote AG.
Draining fuel tank .

• Complete emptying can be achieved, for example, by render‐
ing inert (filling with nitrogen or water) ⇒ page 17 .

• The fuel tank can then be emptied and transported or disposed

of safely.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
le
un
pt
an
d
itte
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erm
ab
ility
ot p
wit
is n
h re
ole,
spec
t to the co
rrectness o
cial p
f inform
mer
atio
om
n
c
i
or
n thi
te
sd
iva
o
pr
cum
r
fo
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
Vo
o
by c lksw
cted agen
Prote AG.
1. Fuel 19
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
Caddy 2004 ➤ , Caddy 2011 ➤ , Caddy 2016 ➤ oris e nte
h eo
Gas drive - General information, commercial vehicles
aut - Edition 06.2018 ra
c
ss
ce
le
un
pt
2 Senders and sensors
an
d
itte
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rm
ab
pe
ility
⇒ “2.1 Senders and sensors”, page 20
ot
wit
, is n
2.1 Senders and sensors
h re
hole
spec
High-pressure valve for gas mode - N372-
es, in part or in w
t to the co
♦ The high-pressure valve for gas mode - N372- -1- is located
on the pressure regulator.
rrectness of i
♦ The high-pressure valve for gas mode - N372- opens the nat‐
ural gas line from the natural gas fuel tank.
l purpos
nform
mercia
a
com
tion in
r
te o
thi
s
iva
do
r
rp
cum
fo
en
ng
t.
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Cop py
t. rig
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pyri by
Vo
o
by c lksw
cted agen
Prote AG.
Tank pressure sensor - G400-

♦ The tank pressure sensor - G400- -1- is located on the pres‐
sure regulator.
♦ The tank pressure sensor - G400- -1- determines the natural
gas pressure on the high-pressure side.
Gas rail sensor - G401-

♦ The gas rail sensor - G401- -1- determines the pressure on
the low-pressure side.
Note
Depending on the equipment, the gas rail sensor - G401- can also
be fitted in the gas rail temperature and pressure sensor - GX21- ,
observe ⇒ Current flow diagrams, Electrical fault finding and Fit‐
ting locations.

Gas rail temperature and pressure sensor - GX21-

♦ Gas rail temperature and pressure sensor - GX21- -2-, com‐
prising gas rail sensor - G401- and temperature sender for
alternative fuel system - G876- .
Note
Depending on the equipment, only the gas rail sensor - G401- can
be fitted, observe ⇒ Current flow diagrams, Electrical fault finding
and Fitting locations.
AG. Volkswagen AG d
agen oes
olksw not
V gu
d by ara
ise nte
or eo
h
aut ra
ss c
ce
e
nl
pt
du
an
itte
y li
erm
ab
ility
ot p
wit
, is n
h re
hole
spec
es, in part or in w
t to the co
rrectness of i
l purpos
nform
mercia
at
om
ion
c
in t
or
his
ate
do
priv
cum
for
en
ng
t.
yi Co
Cop py
t. rig
gh ht
pyri by
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o
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Prote AG.
2. Senders and sensors 21

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Service

Workshop Manual Volksw

Service Department. Technical Information

All rights reserved.

Copyright © 2018 Volkswagen AG, Wolfsburg D4B80860AD6

1.3 Damage assessment catalogue for steel fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1.4 General information on emptying natural gas fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1.5 Rendering natural gas tanks insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

1.6 Disposing of natural gas fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

2.1 Senders and sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

1.1 Safety precautions when working on natural gas system

Risk of fatal injury and explosion from escaping natural gas

2 Rep. gr.00 - Technical data

gas-powered vehicles must receive adequate and suitable induc‐

Why is induction training necessary?

with instructions and induction training on hazards in workshops

requested to provide induction training.

Scope of induction training

How do I identify a gas-powered vehicle?

3. Induction training/staff qualifications 3

In all cases, the country-specific requirements must be observed!

For any type of work on a gas-powered vehicle, the information

4 Rep. gr.00 - Technical data

4 Accepting vehicles with natural gas

4.1 Accepting vehicle for repairs

vehicle must be left in the open and placed under observation.

iced in a normal work area.

4. Accepting vehicles with natural gas system for repairs 5

5 Legal texts and specifications

5.1 Regulations and directives

5.2 Workplace requirements

6 Rep. gr.00 - Technical data

6 Basic technical and physical proper‐

6.1 Physical data of dried natural gas

Dried natural gas does not create methane hydrates. Methane

Chemical formula CH4

sion threshold (OEG): 17% vol.

Relative density (air = 1) 0.55 to 0.75 (lighter than air)

Colour Natural gas is invisible

Effects on metal Contamination of the gas can

Water content Only very small amounts of wa‐

explosive/inflammable vapour/ atio

air mixtures forming during use.

6. Basic technical and physical properties 7

7.1 Rules for cleanliness

cannot be carried out immediately.

8 Rep. gr.00 - Technical data

⇒ “8.2 Checking gas system for leaks”, page 9

Special tools and workshop equipment required

♦ Vehicle diagnostic tester

♦ Different processes are described in this workshop manual for

8.3 Searching for leaks in gas system using

8. Checking gas system 9

♦ Gas leak detecting system - VAS 523 003-

Prerequisites for testing

be used as a definitive means of testing the area. No bubbles

Risk of explosion and danger to life due to sources of ignition in

ignite and cause an explosion. Severe or fatal injury from ex‐