If the bolt is part way out then you need to know that the threads are most
likley damaged and you will coninue to do more damage as you turn the bolt.
The 1.9 engine had 3 differant size bolt lengths I dont know why. You could
heat the bolt  or drill the center out and then chisle the remaining after
the pulley is removed or you could user an impact air gun with a 1/2 inch
drive. I have the tap for this the size is 20 mm X 1.5. The 1.9 cranks are
common and should not be exspencive or hard to find. why are you removing
the pulley.
Bob
http://www.bostonengine.com
----- Original Message -----
From: "Greenamyer, William L" <william.l.greenamyer@BOEING.COM>
To: <vanagon@GERRY.VANAGON.COM>
Sent: Wednesday, December 17, 2003 8:24 AM
Subject: Crankshaft pully bolt

The crankshaft bolt on my 84GL (1.9 leaker) is stuck at about 1/4" of
extraction. Mechanics have told me various ways to try to break it free
(impact tool, jam something into the flywheel, strap wrench, etc) but thus
far, I have only tried the strap wrench since it can't damage anything. Upon
checking the Bentley, it appears that VW actually made tools to handle this
problem and allow proper torqueing of the bolt. The items have part numbers
of 3149 (three piece set) and 3102 (which is a heavy bar with prongs on it).
Has anyone on the list had a problem with a stuck crankshaft bolt or how do
you rebuilders torque this bolt?  Do you have one of the above mentioned
tools or have you made something up yourself?  Do you just jamb something
into the flywheel?  I am looking for solutions to this stuck (and I mean
stuck) bolt.

William