KW Stumpf: How Often to Refill?

Hello,
"Basics: 1994 Golf 3 TDI 1Z, owned since '99, current mileage approximately 120,000 km (assuming the original mileage figures are correct), likely a test engine from Emden, possibly Audi-sourced. Engine control unit with hand-painted chips, stripped wiring harness (Winkler minimal system...)"

I'm having (again) problems with my stator. The starting behavior was poor, and the ESP values were off, so I took the whole thing apart.



"Where the arrows are, you can see the color marking from the last timing belt replacement. The marking on the timing belt sprocket is rotated a few degrees counter-clockwise relative to the crankshaft bolt. That's why my theory is that the bolt itself is tight, but the sprocket has rotated. The adjusted timing/ESP data seems to support this."
"This isn't the first time this has happened. I've already had a stripped screw and a loose screw. When the first screw stripped, it was already a 12.x screw installed (the 94, 1Z TDI was originally supposed to have a 'softer' 10.x screw)."
This means that at least the third gear is damaged (and likely the crankshaft stub has corresponding damage).
VW repaired the damage from the previous dismantling (it lasted 20,000 km), and I addressed the loose screw last winter (I used a stub cutter from KW, and it's been 10,000 km since then). At that time, after talking to a VW master technician, I installed the gear with a very thin layer of Loctite and the screw without any Loctite on the threads, but with a little Loctite on the flange.
If the toothed wheel rotates without the screw becoming loose, then the flat surface on the shock absorber likely has a defect.
Since the flattening is slightly angled, if you were to re-mill it, you would need to go deeper (into the healthy area?).
Has anyone ever repeatedly ground down the same crankshaft? How much material can be removed without causing problems? And does that really help? Or would ultimately only a different crankshaft solve the issue?

That would require removing the engine, and the effort involved (finding a workshop, removing the engine, partially disassembling it, etc.) is honestly a bit too much for me, given the problem. (I'd rather just install something else directly.)

What do you think? Is there still a chance for a repair?
Hi, Marcus.

Hi, I've been back on this forum for a while now. This is just a joke from VW.
I joined this forum out of fear that the same thing would happen to my Golf III. Now, it's been sold for 2 months (196,000 km), and it held up well despite its age. Two of my friends lost their engines on similar trips. I wish you good luck in getting it fixed again!

Okay, so...
The van was towed to VW, they were optimistic and re-examined the issue, and then, with a new gear, they found that there was still play/looseness.
Okay, so: The crankshaft is damaged (three timing gears are worn out at 120,000 km...).
"Used crankshafts aren't necessarily a guarantee of reliability for the engine, especially considering the potential issues. I've heard that there are companies that weld material onto damaged areas and then re-machine the part to make it fit again. This can be done for a relatively low price (compared to a new crankshaft), often under 100 euros."
Has anyone had any experience with that?
Hi, Marcus.