On our 2.0L Neon the pulley was so tight we were bending the pulley before it was coming off the crank. We ended up heating the pulley up with "the hot wrench" before it would even budge. This was a factory pulley/installation! We actually honed the pulley to loosen up the fit so we could get it back together. I say make the clearance so you need to heat the pulley up to ~300F before you can get it on. That seems to be the way the factory did it!