1. The FSM wants you to smack a new crank seal into the timing cover AFTER installing said cover. I didn't do this (with the A/C condenser in the way, how was I swinging anything at a seal?)
And lining up the timing cover itself was not a big deal. Just go easy (but get it on...FIPG is setting up) and it goes into place.
I agree with you, lining up the cover looked tricky but you just gotta send it.
2. Cam towers are notorious for leaking. I certainly wouldn't do all this work and skip the cam towers even though that would save the timing chain and gear work. You're already there. Just peel the gears and chains off and remove the bolts for the cam towers. It's worth it.