Can't fully answer your question, but:
1.
Positioning the bottom pulley keyway up is not the correct procedure. I'm not saying that it's definately wrong. Normally the TDC mark is on the alternator pulley that should be aligned to the mark on the belt casing.
2.
The cam pulley keyway should point directly down when #1 is at TDC. The standard pulley has an arrow up at that point.