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====== After Market ECU in Corrado G60 ======

//Work in progress//

**NOTE I'm not car professional, just DIY guy. I don't take any responsibility if you break something based on this article.** 

G60 (code PG) engine came equipped with Digifant engine management. This is all electronic and can also be reprogrammed changing custom chips. There are various chips for various combinations, some might be able to also reprogram it with EEPROM reader. But same time this ECU also show some age, with only narrow-band oxygen sensor, distributor etc. Since its all digital, conversion to aftermarket ECU is "relatively easy". I have run G60 with Megasquirt and now later making new build based on MaxxEcu. Here are some notes, I've taken.

===== Triggering =====

G60 has 4-teeth Hall sensor inside distributor. There is 3-wire connector. Pinout

  - Ground (ECU)
  - Signal (ECU)
  - +12V (ECU)

It works also with +5V. With Megasquirt you probably need 1k pullup resistor between +5V and signal wires. Harness connector is probably something you need to take from original harness. Junior Power Timer pins fits into this.

{{gallery>corrado:?vw_g60_distributor*.jpg}}

For upgrade you can look trigger wheel found from newer VW:s part number 036105189C . This is 60-2 trigger wheel found in many later VW engines and is actually backwards compatible. It installs as crankshaft seal undel flywheel, so it is a lot work to install since you have to remove gearbox, clutch and flywheel in order to install it. On the otherhand this will be very protected location. Triggerwheel is just pressed on crankshaft. One flange bolt hole is misaligned to block holes, I drilled and tapped new hole though it probably would be fine without it.

{{gallery>corrado:?vw_60-2*.jpg }}

For this triggerwheel I have Hall sensor, partnumber 030957147 (X). In my understanding VR sensor should also exists but I have no number for that.Clutch housing has small steelplate covering hole behing engine block, this needs small cut for the sensor wire.

{{gallery>corrado:vw_hall_sensor.jpg}}

===== Fuel system =====

Corrado has electronic fuel injection. Depending on year of manufacture there is one or two fuel pumps. My model has one in tank, originally Pierburg unit which broke down and later on has been replaced with Bosch pump. Bosch part number is "F000TE0111", which fits with single pump models. If you are replacing Pierburg pump with Bosch, you need also new fuel gauge sender unit. That Bosch pump should produce 150l/h at 3 bar pressure.

Pump is controlled by fuel pump relay, which is controlled by ECU. Control wire goes to original ECU, wire color for relay control is red-yellow and conviently there is another red-yellow wire which comes from same fuel pump relay output. Near ECU there is 3-pin connector and 4-pin connector. 3-pin has following wires:

  - red-white = power from mains
  - red-yellow = fuel pump relay control
  - red-yellow = output from fuel pump relay control

Injectors are Bosch 037906031D, 245cc/3bar (I cannot 100% verify that). High impedance, can be used as is by many engine management systems. Body type is EV1, wiring connector is Jetronic/Junior Power Timer. You can get bigger EV1 body injectors, or look for newer Bosch EV6/EV14 60mm body injectors which should fit also.

Note that original injector wiring is very likely brittle and should be replaced. Also original fuel rail is plastic, mine seemed fine for 30-year old plastic but you never know. Replaced it just in case and to ethanol-proof fuel system.

{{gallery>corrado:?corrado_g60_fuel*.jpg }}