Originally Posted by Grumpy
I'm now not sure what you've done, but you have to lop off the head of the bolt. In other words, all you should have left is the end of the shank diameter of the bolt. If you grind it flush with the washer (photos of a 1.6 on a UK website clearly show the loose washer under the head of a removed pulley bolt) and reasonably flat it might help if you have to use a puller. The washer should be protecting the pulley during all this grinding. You won't see the keyway (groove) until the washer is off.
which UK website is that please? I'll take a look!
Obviously I can't see the back of the washer yet, but the front is NOT manufactured 'FLAT' - IT IS A DOME SHAPE!! i.e. a slight curve, highest point in the centre where the bolt head was previously situated!