Originally Posted by jon@work

if the engine's out of the car and you're removing the crank anyway, then :

1. take out the crank complete with the pulley and front cover,

2. get a B+D workmate and open it up so that the crank can pass through the gap between the jaws

3. support the crank vertically so the front cover takes the weight on the workmate

4. put the pulley bolt loosely in the end of the crank and smack it with a deadblow - get ready to catch the crank as it falls off the previously stuck pulley

this way, you've got a good chance of not damaging the front housing