When going to TDC on compression stroke I noticed that the notch on the harmonic balancer was off by about 3 inches from the timing pointer mark give or take.
You might wanna take a closer look at the balancer because the notch youre referring to,cut into the balancer, is NOT the TDC mark (on a oem or oem replacement balancer) The part of the balancer where it gets thinner is where the timing marks are located.The notch is cut into the thicker portion of the balancer.If you view the pictures below,you can see the timing marks stamped into the balancer.
atdc 10° ¹ ¹ ¹ ¹ 0° ¹ ¹ ¹ ¹ 10° btdc
When youve got the number 1 piston at tdc on the compression stroke,the balancer mark with the number "0" should be aligned with the timing pointer.Once youve got the crank in that position,with the 0 mark aligned with the pointer,drop the distributer in the block so that the rotor is pointing to the number 1 position on the distributer cap.If youve got the efi system with the upper and lower intake vs a carbed setup,the rotor should be pointed slightly to the left of center/between the front 2 upper intake bolts.
( It should look identical to the rotor position shown in the 3rd picture at the bottom) if youve got the distributer indexed (dropped in the block with the distributer base fully seated)
Once youve got the distributer indexed correctly,youll have to start the engine,pull the spout plug (attached to the ignition module wiring harness) ,rotate the distributer til the 10° btdc mark is aligned with the timing pointer,tighten the distributor bolt then reinstall the spout plug.If you fail to remove the spout plug,before adjusting the distributer,the timing will be way too retarded because the computer automatically advances timing another 10° once you plug the spout plug back in.Timing will be retarded by 10°,if you fail to remove the spout plug beforehand,which means,instead of it being at 20°,which is where the timing runs with your initial setting of 10° plus the 10° of advance added by the computer,it'll be at 10° instead,so youll lose power in all ranges.
The 3rd picture shown below is the direction the rotor should be pointed towards while the 0° mark is still aligned with the timing pointer and the distributer is seated completely (bottomed out on the block surface) with the rotor pointed towards the #1 position on the cap.
The following link details the distributor indexing & timing procedure,if the instructions above are not clear enough.Once you click on the link and the page opens,scroll down to post #2 & #3.Ignore post #1,its used for replacing the pip sensor.
Good luck on the project. TFI PIP Sensor Replacement Procedure