No problem mate! If you manage to find out what is causing this, post here as it might help someone in the future (and I am very curious as this was the very reason I sold the car!) :grinning:
Mine was the main bearing in the gearbox as well, mechanic fixed it by inserting something into the gearbox, I assume what the guy in the video above did.
https://www.darksidedevelopments.co.uk/products/amc-complete-cylinder-head-for-2-0-16v-pd140-bkd-engine.html There you go. :)
What I did, I took a used cylinder head from Passat B6 which had C revision and was BKD engine. Also took camshafts, valves and everything that goes inside the head...
I had probably dozen of mechanics tell me it's not the head. Other symptoms would sometimes include a puff of white smoke on cold start and if I'd leave car standing for 2-3 days after a long journey (so the coolant was pressurised completely before turning the car off), I'd have odd startup...
I totally understand you mate, I went through it all a few years back. Replaced everything that could cause the leak and in the end removed the cylinder head and I had a crack to see. :(
In order for DPF to function without getting clogged, all other systems need to be fully functional.
What I mean by that is that if injectors are leaking, you'll get more soot, if timing is not spot on, you'll have more soot, etc.
I would also look at these aspects of the engine as new DPF...
Being a 2003, you're almost guaranteed your cylinder head has seen better days.
Edit: To clarify, I'd be certain it's porous and leaking water into cylinder.
Thi is a very nice thread to see. I had the exact same engine a while back and I am still in love with it. Keep us updated if you do any other changes! :D
Shouldn't the clutch be the same on all non S models if gearbox is the same? If so, 2.0 TDI 8P can hold anywhere between 405 and 435Nm so I'd say you're perfectly fine with stage 1.
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