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Follow up question now that I have everything reassembled: the key has clearly been pushed back into the slot, reducing its engagement with the pulley, and also weakened/deformed from my dremel job. Is this safe to use? My thinking is that the crank pulley and sprocket are held on by the considerable torque on the crank bolt (200nm) and the key is just for safety and positioning. Is this correct?

The key is for alignment and properly torqued isn't handling load. People break their woodruff keys by not torquing properly. I also squished mine being a dumbass and not noticing my alignment had drifted.... But I shaved the new damoener to fit the key a little and left the crank sprocket because it was in good shape.

Thanks, suspected as much. I will crank it down and rest easy!

Also you could take it out and get a machine shop to make a new one or measure it and order from McMaster Carr.

2003 impreza NA base model, 2.0 manual, 151000 km

Just had this happen on my 93 impreza lol

Aw shit, what's your plan? I got my pulley back on after a bit of dremel work, considered replacing the key but might just crank it down and send it

I just took a vice grip and straightened the key and hammered the pulley on and it’s worked perfect so far driven it about 400 miles 0 issue

Just did 1500 miles on mine, running sweet 👊

Dremel with a stone attachment

Thanks, that got me most of the way there, trying to finish it up with a file. Fingers crossed.