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It looks like you're all over it. The small square notch on the pulley is in the right place. I'd be inclined to think there may be crud in the hole, or the key is a little bit off or too big rather than think the hole is not not there. I saw somewhere that an 8 mm drill bit fits, so if that's an 8 mm key, it may be be too big. The real key is to be at TDC to unload the camshafts, and you're there. As far as unloading the cams is concerned you don't have to be perfect, a degree or so won't make a difference. If I can find a picture of the third tensioner, I'll post it here, and yes, that's a challenge to everyone else to see who can post it first.
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2003 S manual
Last edited by Jamesp; 02-18-2015 at 05:15 PM.
Reason: typo
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