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Well, as long as you rotate the engine clockwise, and get the harmonic balancer at 0 degrees, and the distributor rotor is lined up to the notch, AND cyl #1 is at TDC, you will be OK again (that last part is very important - remember, engine spins 2X for every 1X of the distributor. Otherwise, you aren't going to start - trust me on this, I know). Keep in mind that the distributor is not "keyed" in any way.
On the pulley, you describe exactly why you have to remove the pulley+banancer. Looks like it should work, but doesn't line up quite right, and won't.
NOW you know why they charged $900!!
Having a water pump poop out that soon leads me to beleive that the belts might have been too tight. It's been my past experience that bearing/seal wear goes up exponentially with overtensioning of the belts. Because I lost my "feel" for how tight a belt should be, I bought this little gadget from Gates (a Kricket) that measures belt tension. It was fairly cheap, but it is also very hard to find for some reason.
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