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3. Could the replacement bolt+washer be slightly too long, bottoming out in the crank rather than applying the full torque to the pulley?


I'd start here. take the front pully (harmonic balancer) off, then by hand thread in the bolt and washer combo and make sure it can be screwed in flush to the end of the crank. Should spin in easily with your fingers all the way. Make sure the washer is installed in the correct direction too.

Woodruff key next maybe, but that is a lot of work being you have the timing belt on. Like starting that process over.

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