Abstract On-board generation of hydrogen from methanol with a reformer in connection with the use of a proton-exchange membrane fuel cell (PEMFC) is an attractive option for a passenger car drive. Special considerations are required to obtain low weight and volume. Furthermore, the PEMFC of today cannot tolerate more than 10 ppm of carbon monoxide in the fuel. Therefore a gas conditioning step is needed after the methanol reformer. Our main research activities focus on the conceptual design of a drive system for a passenger car with methanol reformer and PEMFC: engineering studies with regard to different aspects of this design including reformer, catalytic burner, gas conditioning, balances of the fuel cycles and basic design of a compact methanol reformer. The work described here was carried out within the framework of a JOULE II project of the European Union (1993–1995). Extensive experimental studies have been carried out at the Forschungszentrum Julich GmbH (KFA) in Germany and at Haldor Topsoe A/S in Denmark.