Chrysler Repair: 2.7L 05: timing chain replacement and cam shaft replacement, timing chain replacement, shaft replacement

Question
QUESTION: Thank you for reading my question.  I have been working on my car that broke a timing chain in December of last year and taking it apart I had 4 bent valves.  I took the heads to a machine shop to replace the valves and pressure check and clean the heads and reseat the valves as well.  I have followed my manual to a t and where I am getting stuck is the timing.  I am supposed to line up the crank mark and oil pump mark.  Did that.  Problem is we went through several revolutions of this (while the heads were off of course) and every time the marks lined up, the #1 piston was only 3 quarters of the way up to TDC.  I have always thought that you had to have the #1 piston at TDC to time everything.  When I align the marks on the crank/oil pump the piston is 3 quarters of the way up.  I put the heads on and put everything in and placed the camshafts in with the 12 links inbetween at the noon position and the sproket bolt holes dont line up.  Is it possible that the #1 cylinder IS supposed to be at TDC and the mark on the crank is off??  When I put the main timing chain on with all the marks in the correct spots the cam sprokets and cam bolt holes are about a 1/2 inch off on both sides.  Please help!!!!

ANSWER: Hi Chris,
The Chrysler '05 manual (on CD) for the 2.7L used in the Sebring says the timing mark on the oil pump is at 60 degrees after top dead center when aligned to the crank mark. So that would explain the discrepency that you observed. There are about 10 pages in the '03 manual (shows the same explanation about the timing mark) that cover the entire timing chain/valve timing procedure of the engine. If you don't have the Chrysler shop manual let me know and I can xerox a copy and postal mail it to you on Monday. If you would be so kind as to send me back four 44-cent stamps to cover my costs after you get the pages that would be appreciated.  
Roland
PS Please 'rate' my answer, and where you see the question about 'volunteer of the month' please consider a 'yes' answer if this response has proven helpful. Thanks

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QUESTION: OK please send me the pages in the mail and I will definitely send more then stamps your way.  I am curious about the 60 degrees?  Not sure what you mean by that and one more question.  When it says have the secondary timing chain at noon, does that mean noon to the heads or noon straight up?  Same for the main chain.  I know this question sounds redundant, but I have racked my brain about this and just want to make sure everything is ok with what I am doing.  Thank you!

Mailing address is 3496 West 97th Avenue Unit 77  Westminster Colorado 80031

ANSWER: Hi Chris,
I would understant 60 ATDC of cylinder 1 to to mean that when the timing marks are aligned that the crank shaft has rotated 60 degrees past when it was at TDC in a clockwise direction (or another way of saying it would be 300 BTDC*, though that is not the typical way to describe its position). The 'noon' designation means noon as compared to the surface of the head as the horizontal frame of reference. It sounds like you don't have a very clear instruction set, so it will he helpful to get the pages that I will send on Monday.
Roland
PS No need to send more than the stamps, but I would appreciate a 'rate' and a 'yes' answer to the question should I be 'volunteer of the month'.
*Note that ATDC and BTDC are usually with reference to the compression stroke, and since the crank rotates twice for each full cycle it would actually be 660 BTDC of that stroke. But because you don't have the valve timing chain in place at this point in time the reference as I would describe it would not include the full extra 360 rotation to get to compression max position.

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QUESTION: OK.  I have not had a chance to work on my car since we have last talked.  The only way I see to move forward is to set the #1 cylinder at TDC and place the cams in the way the instructions show with the 12 links inbetween the colored secondary mark as they are positioned on the cam timing marks.  Then set it in the heads at 90 degress.  The oil pump mark and crank mark do not line up when the cylinder is at tdc but i dont know how else to get it timed right.  Everything I have read says that the engine is timed right when all this happens.  As we spoke about before, If I line the oil pump and crank mark up the #1 piston is 60 degrees form tdc.  So tell me what you think.  I am going to set everything like I told you, then time the main timing chain to the oil pump even though the crank mark doesnt line up.  I will then rotate the crank manually to see if anything is hitting.  What do you think?

Answer
Hi Chris,
Did you get the pages? I believe I sent them to you but don't keep a log.
If not, let me know and I will do it for sure. Because of issues of interference, you will have to be very careful about rotating the crank shaft very much absent some sort of compensating rotation of the cam shafts in order to avoid collisions between the pistons and the valves. I don't quite understand what you are proposing to do. I would suggest waiting until the manual pages are in your hand.
Roland