If you recall, what was the game version before you patched it? After the 1.45 patch was released the Larians updated the master for the CDs to 1.46. If you have the updated CDs, it is possible the size difference in the intro video is just from it being revised after the initial release.
The confiv.div file stores options, so changing the resolution, FSAA mode, Fog (in the configuration program) or gamma (from within the game) will result in a different file size and/or CRC value. You can open the file in Notepad (or any other text editor) and check out the contents.
It would be informative, though not necessarily helpful, if we could track what the configuration test does before it crashes. Sysinternals has a program which can monitor file access, which could help determine if the crash occurs when the configuration program is accessing files related to the game, graphics drivers or DirectX.
If you want to give it a shot;
[*] download
Filemon and extract it somewhere (no install is required).
[*] Shut down all non-essential programs (try to eliminate as much as possible), except for Windows Explorer, then start the game's configuration program.
[*] In Windows Explorer, double click on the filemon.exe file to start the program. After it loads, click on the menu Edit | Clear Display (or hit Ctrl-X).
[*] Switch to the configuration program, and hit the Test button. When the error comes up, leave it there, switch back to Filemon, and click on the magnifying glass icon to stop monitoring file access.
[*] If you don't want to look through the resulting list, save it and either post it or email it to me (divineone at shaw dot ca).
