Just re-installed my crankshaft pulley bolt on 2003 blob, started with 44nm, marked the pulley and put the car in gear with handbrake on - tightened the pulley to the recommended 127nm and checked the mark against the belt cover guide and the bolt deffintely didn’t exceed 45 degrees before hitting torque.
Manaual says if it’s less than 45 degrees then replace the bolt - is this really necessary?

 

For the cost of a bolt, why risk it?
My suspicion is the bolt and washer are designed to give in service to maintain an adequate clamping force when things expand. The bolt or washer may have work hardened, reducing it's tolerance to temperature changes.