I think both you and the mechanic are focusing on the wrong things. You are confused by his insistence on referring to TDC of 1 & 4. Both ARE at TDC when the crank gear is aligned with the mark on the INNER timing cover. However the distinction is made when the timng belt is installed - with the cam aligned with the appropriate mark--making #1 TDC on the COMPRESION STROKE and #4 TDC on its EXHAUST STROKE. In order not to confuse matters he should not bring in #4 as a factor. With the cam aligned properly and the crank gear aligned #1 will be at the correct TDC compression stroke and that's that.
He should stop thinking about the mark on the crank PULLEY -- that mark is made to align with the scale on the OUTER belt cover -- and looking from the front, it is to the right of the INNER cover mark. If the crank gear and washers are installed correctly on the crankshaft and the crank pulley is installed correctly on the NUB of the crank gear you have a proper installation. -- Dave
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