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Jason you bring up a good point with the tensioner pulley. You will need a spanner wrench to set the tension on that pulley. There is a spec on pulley tension. You can probably find that on the Chiltons website. Search Chiltons in the forum to get access. If you don’t have the proper spanner wrench, you can attempt 90* needle nose pliers, but that will be the hard way. Good luck. Post your experience when done.
As far as contact cleaner goes I like Wurth Contact OL. It’s the stuff to use. Expensive, but wor every penny.
http://shop.bevelheaven.com/detail.aspx?ID=818
One can lasts a good while.You will have mark on the cam and crank. Assuming this is a 4 cyl. This vehicle has a balance shaft too. Make sure that you correctly align the balance shaft belt. The shafts will have timing marks on them. It has been a while but the oil pump may also have a mark. Remember to route the belt so that she slack is on the tensioner side. What motor is in the car by the way?
The purpose of the reservoir is to catch the coolant that the radiator cap purges in a high pressure situation. As the system reaches a specified pressure the cap opens allowing coolant to escape lowering system pressure. As the car cools down it allows coolant to back fill into the radiator. Was the cap you put on OE? I have seen aftermarket caps fail soon after install. It sounds like the system achieves high pressure (which is good) but the cap remains open too long.