Diamond Disc for Stripped Screw Removal.

Yes, I am probably one of those people who rack their brains over the ultimate solution to the "killer screw" problem .
I have now removed the AFN belt pulley from the Sharan.
The screw was already of a newer type, and it seems that the KW stub axle had been planned before.
I can't say exactly how long ago it was, but I suspect it was done during the last timing belt change, which was 80,000 km ago.

Now I've read that this problem also affects the 2.5 TDI engines in the T4.
There is also a diamond dust-coated disc available for this purpose, which is screwed between the KW stub and the timing pulley.
http://t4-wiki.de/wiki/Diamantscheibe
For the 1.9 TDI engines, the dimensions required are 30x15x0.1.
Because the disc from the T4 has a larger inner diameter,
Of course, this would also reduce the contact area, which would likely be counterproductive.

Is there anything like that available for the 1Z/AFN engine?

Another problem I'm having is that the KW Stumpf seems to have been over-engineered.
"This is why the serpentine pulley is rubbing against the timing cover."
Is it possible to counteract this in some way by using washers, or would this negatively affect the centering of the pulley?

Thank you in advance for your contributions .

Tagessuppe wrote:

There is also a diamond dust-coated disc that is screwed between the KW stub and the timing pulley wheel to solve the problem.

That's not entirely correct. The 2.5 models are built differently.
The surface pressure occurs there between the crankshaft (KW) and the vibration damper (Schwingungstilger). The timing belt pulley is connected to the crankshaft only via the groove, and the 4 Allen screws are connected to the crankshaft via the damper.