Ha...That crank pulley bolt can be a pain... I replaced my timing belt last year and removed the bolt using the "crank the engine with a breaker bar on the bolt" method which worked fine. When it came time to put it back on, I beat the heck out of the breaker bar with a ball peen hammer to tighten the bolt.
6 months later, as I'm cruising down the highway, I hear a loud clunk under the rover, but no unusual indications otherwise. Nothing noted on a casual inspection at my destination.
On my way home that night, the charge light comes on a half mile from my house. I pull over to find the fan belt is missing, and the crank pulley has slid halfway off the crank. Now I know what that clunk was.
I eventually squirted blue loc-tite all over the replacement bolt and ball peen hammered it on again.
Just last night, I removed the same bolt to tear down the engine for a complete engine rebuild and I had to use an electric impact driver to get it off.
LESSON LEARNED: Use generous amounts of loc-tite when installing this bolt, not just your usual lilttle spot of it.
--Mark
1973 SIII 109 RHD 2.5NA Diesel
0-54mph in just under 11.5 minutes
(9.7 minutes now that she's a 3-door).