Why are you guys rotating it 5 times? I always did 6. I remember if the b.shafts are deleted less rotations are needed (4?), but I always did 6 to verify it's all lined up.
But yeah, like said above. Get the belt on there, PROPERLY do the tensioner. Meaning slowly let it out, wait 15 min, check the gap. If it's wrong, redo it. It always takes me a few times. Don't rotate shit until the tensioner is correct AND the gears are lined properly. Turn the engine the opposite way 1/4 turn, put it back. Verify the gears are still lined up and the tensioner is within spec. Then turn it over 6x. Everything should line up again and the tensioner should still be within spec.