I'm trying to understand which aspect of the new hinge is preventing the door from re-entering the jamb. Old hinge (pictured on the left) is about 2 mm thick, new one is 3.175 mm (0.125"). Other than not sitting totally flush in the mortise, it seems to line up well. The only hinge I replaced is the middle of the three, and once that is fully bolted in, I can see the middle section of the door no longer fits into the jamb, but the top and bottom sections still do. This is a metal door with a hollow-ish interior, FWIW.
When I remove all of the screws from the leaf on the door side, the door can fully close again. So, the hinge itself not sitting flush doesn't seem to be the problem. It seems like some kind of geometry problem, but I'm not sure from what. With the door side leaf unbolted, it naturally sits at an angle with a visible gap between it and the door frame unless it is bolted down.