Passport back on 10:15 am today! CIC got it 10 am on Sep 25. Posting this on behalf of my GF, my signature shows my timelines.
For landing: When you drive to US customs, everyone on the car must have passport, you can drop your co-traveler at Canadian side if they are not going for landing.
US will give you a procedural/administrative refusal and bring it back to Canada customs. I had concern about this refusal but when I applied US visa a month later, I got 10 yrs US visa without any problem.
PR card: I was told at border to wait 2-3 months and I got it around 8 weeks. You can check PR card application status the same place where you check PR application status after 4-5 weeks after landing.