A great challenge in a passive direct methanol fuel cell (pDMFC) is how to reduce both methanol and water crossover, from the anode to the cathode side, without significant losses on its power output. Different approaches including improving the membrane and modifying the cell structure and materials have been proposed in the last years. In this work, an experimental study was carried out to evaluate the effect of the cathode diffusion layer (CDL) properties on the power output of a pDMFC. Towards a cost reduction, lower catalyst loadings were used on both anode and cathode electrodes. Since the main goal was the optimization of a pDMFC using the materials commercially available, different carbon-fibber materials were employed as CDL. The experimental results were analysed based on the polarization curves and electrochemical impedance spectroscopy measurements with innovative electric equivalent circuit allowing the identification of the different losses, including the activation resistance of the parasitic cathode methanol oxidation. A maximum power density of 3.0 mW/cm(2) was obtained using carbon cloth with a lower thickness as CDL and a methanol concentration of 5 M. (C) 2019 Hydrogen Energy Publications LLC. Published by Elsevier Ltd. All rights reserved.