TDI Unable to select gears

[BlackSeedyEye]

Hiya,

Have now completed my engine conversion from PD115 to PD150 spec usuing a 130 block, 150 turbo and intercooler.

Have pressure bled the hydralic clutch and yet the pedal still feels very soft and I am not able to get in to any gears when the engine is on. Am able to select all gears when the engine is off, but the pedal just does not feel half as firm as it did prior to the engine replacement. Before putting any more time and money in to this I really want to narrow down what the problem could be and what symptoms relate to what.

I thought the clutch might have been fused to the pressure plate from when the engine was out of a vehicle in the breaker yard or when it was in transit so I have started the car in gear and was able to drive it in a lap around my road and even get the car to a standstill when I pressed the clutch in but I could still not change gear. Have also tried accelerating hard to see if the opposite happens and if the clutch slips but this seems fine, with the road that I had available.

Any pointers as to what could be up with my car and are there any other ways to narrow down what's happened?? I thought the release bearing maybe the wrong size but I have now confirmed that it was the same for my engine and clutch/flywheel assembly as what is in there now. I hope to hear from you soon, many thanks in advance

 

[devonutopia]

So the gearbox is the same one? When I did my vRS conversion, I got the 6 speed box and all other bits with it. If you're using the oem 5 speed box with the 130 block and internals, there might be a mismatch there? I also had to change the gearbox linkages and effectively put the whole 6 speed gearstick in, complete with cables. Obviously my engine/box combo came joined up with correct clutch so no issues to overcome there.

Have you changed anything up top too? Injectors? Head? Camshaft?

 

[BlackSeedyEye]

Yes my original engine was already a PD model so it had the 02M gearbox which is used through the Golf PD range.
Regarding the block I used, I was told that it had 30k miles on it, and it looks like it's only done a low amount of miles but much to my annoyance it didn't confirm the miles on my receipt.
I had it confirmed through other questioning that the ASZ and ARL (130&150) blocks are identical almost all the way, differences are tiny and they do not include injector or cam timing differences so they should be safe to tune up to the same level.
Had a very helpful and promising call from Simon at CCCTech (Upsolute) stating that he can reflash my original ECU with the 150 remapped code. Excellent result, just need to be able to select some gears now, any pointers??