Is there anyway the timing chain cover can be put back on without removeing the oil pan?.

Yes you can. You just need to trim the oil pan seal a bit then use silicon in the corners to prevent leaks. It's kind of a biotch to do though and get it right, but it can be done.

yes, no problem, don't try to use the front rubber oil pan seal, just use a good thick bead(1/2") of rtv along the lower oil pan section and instal the cover, make sure there is good coverage all along the cover to pan....I even smooth sealer along the groove to make sure...Rob