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Have just dealt with the same problem. In early efforts, knocked a divot out of the cast iron pulley. It was hard to find a straight line to hit the back of the pulley. I could not get arms of a two leg or three leg puller to hold in the tapers of the pulley and there was not enough space to get the legs behind it. Soaked it all in INOX for a couple of days. Applied heat (propane torch). Still no success. Made up new legs for two arm puller out of 3mm mild steel with an angle grinder. The arms could be rotated into position in the pulley slots then reattached to the puller cross bar. First attempt, the lugs straightened out . Rebent the lugs and heated the puller arms redhot and dropped into water in an attempt to harden them. Tried again (with propane torch heating the hub of the pulley) and gentle tapping and at last it came off. Lower plastic belt cover was damaged by the heat and I had to find a new one. No obvious reason why the pulley was so tight, although there was some evidence of rust. I cleaned this off with steel wool and Scotchbrite.
The crankgear was also stubborn but, after warming it up with a couple of litres of boiling water, I was able to slide it off. I'm still waiting for the new harmonic balancer to turn up in the mail.
On a related issue, when replacing the water pump I was unable to to stop it leaking from the gasket on the block face. It turned out that last time it was replaced, silicone sealant had been used and there was enough in the bolt holes to stop the bolts pulling up all the way. It was fine once I had pulled the pump off again and cleaned the holes out.
Andrew
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