Hi Charles,
Crystal SDK does not have a Field mapping API set so what happens if you try to set location to data source that doesn't match what is saved in the RPT file the Auto-Mapping function in the Engine simply deletes any Field references from the report and that can cause problems of course.
Only thing I can think of is either don't call Verify database or don't save/use/publish reports that the data sources don't match.
CR assumes the table structure does not change from when the report was designed. If it does then you need to manually update the RPT in CR Designer and call Verify database. CR Designer has a mapping UI build in so if the field types change the UI will pop up and you can match fields.
As for crashing w3wp process try looking the IIS logs and see if it gives you more info and details on where and what dll caused the issue.
Try DebugDiag to see if it catches more info.
Don
