Timing a LS180, LS190 Engine for Injection Pump Removal

The New Holland engines used in these loaders are not marked with timing marks or at least none that are accessible while the
engine is in the loader. It is important the engine and injection pump be timed before removal of the injection pump and whe n
installing the injection pump.

Following is information on how to accomplish timing the engines without relying on timing marks. You will need to make thre e tools
to perform the removal of the injection pump. A threaded plate to pull the gear off the pump , a pin to drop into cylinder one to help
locate TDC, and a pointer used in marking the crankshaft pulley are shown in the pages below. I added a fourth tool not shown. If
you read the instructions through you will be told to measure the crankshaft pulley a certain distance from TDC depending on which
loader you are working on. Instead of measuring the distance, which is not easy, I took a thin shim and cut the shim to the length
given in the instructions. Now when TDC is found, just lay the shim on the crankshaft pulley with one end on the TDC mark and then
mark the crankshaft pulley at the other end of the shim.

Also shown in the tool section is a special tool from New Holland. You do not need this tool to time the engine and remove t he
injection pump. The tool is used to set the injection pump at the proper setting and then the injection pump is locked. The locking of
the injection pump is shown in the instructions and must be done to keep the injection pump at the proper position for instal lation. A
pump from a rebuilder should already be timed and locked. Do not unlock the pump until the injection pump Is installed.

When the engine is timed properly for the removal of the injection pump, the injection pump mounting bolts will be accessible
through the holes in the injection pump gear. If the bolts are not accessible the timing procedure was not done correctly or you did
not have number one cylinder on the compression stroke when you started the procedure.
 SPECIAL TOOLS
You will need the specialtools listed in this section to
r* {^ perform the procedures contained in this Tech-Com'

To time the engine and lock time the pump, you will
need:
. NH01341, Degree Wheel, 1, Figure 2

NOTE: The sptined shaft, 2, Figure 2, is included with

the degree whee!, but it is not required to time the
DP200 series PumP.

Tt810077
2

NH01342, Pump to Degree Wheel Adapter, 1,

Figure 3

hr
a Fuel lnjection Pump Drive Gear Puller, Figure 4
a Woodruff Key, Part #72769
3

5oo

Tt810072

Fuel lnjection Pump Drive Gear Puller

1. Bolt5/1 6 - UNFx2 in (51 mm),With integralwasher (3 3. Holes 0.375 in (9.5mm) dia on 2.2 in (56.87mm) dia
Bolts reouired) equally spaced'material of 0.394 in (10mm) Plate
2. Bolt 3/4 i tO - Uttc x 2 in (51mm) HRLC P&O Steel.
 SPECIAL TOOLS . Tir

The degree wheel and pump t9. qgqP." wheel --\

also available as a kit, NH01384' Figure
However'
s. Ait items shown are part of kit NH013B4'
"Jupt"i""t"
1' 4' and
il J;;"t need the splined shaft, Ip:I"
bpS titing gauge, 2, to lock time any DP200 Series
pump'

To perform the alternatetiming procedure on engines

timing marks are NOT
*nLi" in"
e--@
engine flywheel
or the fiywheel does not have timing
".""".ibf"
marks, You will need:

.
M
Fuel lnjeciion Pump Drive Gear Puller
20012272

. Piston Position Tool, Figure 6

prsroru POSlrloN TooL

5/16" - 18 Nuto.
,gr!ry

Base --
5001 5706 - I

cut head off caPscrew

Iib b-nZhter sharP edge

5/16"-18x6" caPscrew

5/16" - 18 thread
o.325

.75" <- BaSe

1- 5/16" - 18 nut
e635082
0.325 0.4't \en:
1.96"
2.60"
@
material 0.75" wide x .375" thick so01 5706/5001 6637
plate HRLC P&O Steel
 SPECIAL TOOLS
. Timing Pointer, 3 Cylinder, Figure 7
F-r 3 CYLINDER TIMING POINTER

90" bend

*-r -0.31"
7.9mm
- 0.31"
7.9mm
L40"
.38" (9.7mm) .38"(9.7mm)

h-.gs" 5.10"
24.1mm 129.5mm

0.100" thick HRLC P&O Steel

2.5mm

5001 6638

A,-
 SPECIAL TOOLS
This proc
a Timing Pointer, 4 Cylinder, Figure 8 engine fl
a Woodruff Key, part #72769 models:

4 CYLINDER TIMING POINTER . 903C

. 774C
. TS9(
. 345[
. LBT|
. 555E
. 255(
. HWi
. 393(
. 561(
. 661(
. 761(

5001 5705
. 701(
. 801(

NOTE:
and cou
end of tl

The fuel
fortimin
90"bend .-] a speci
.75"
19.1m m I .40"
injectior
removir
.45" (11.4mm) .30"(7.6mm) 1. Dis<

LI 2. Clet

.38'1 3.87" _ 3.30"_ )3-1.25" SUTl

9.7mm 98.3mm 83.8mm 31.8mm 3. Sht

fuel
0.100" thick HRLC P&O Steel
2.5mm
4. Disr
fuel
wirr
50016639

B
5. Dis,
all<
Next, we'll look at the steps for removing the fuel 6. On
injection pump. To review this section, answer lift 1

question 2 in the Dealer-Certified Technician Test. clei

 ALTERNATIVE METHOD FOR REMOVING THE FUEL INJECTION PUMP
This procedure is for engines where the engine
ffywheel timing marks are NOT accessible or the
flywheel does not have timing marks. This would
include New Holland Skid Steer Loader models:
o L865, LXB65, LX8B5, LS1B0 (3 cylinder)
. LX985, LS190 (4 cylinder)

NorE: The direction of engine rotation, clockwise

and counterclockwise, is as viewed from the flywheel
end of the engine.

The fuel injection pump must be removed for timing.

This process involves setting the engine to a
specified basic timing position, locking the fuel
injection pump drive shaft into position, and
removing the pump.

1. Disconnect the battery negative terminal ,

7 9//
1,
Figure 34. Ir

2. Clean all dirt from the fuel injection pump and

surrounding areas

3171-08

34
3. On 3-cylinder engines, loosen the air tube clamp,
1, Figure 35, and remove the tube , 2.

35

20
tlP ALTERNATIVE METHOD FOR REMOVING THE FUEL INJECTION PUMP
4. Remove the crankcase ventilation tube, 1,
Figure 36.
5. Disconnect afl fuel lines from the pump and cap
all openings to prevent dirt from entering.

W,

6. Disconnect the throttle cable , 1 , Figure gT, the

flllli
fuel shut-off solenoid wi re, 2, and the wax motor
..11' IIUU/J
wire, 3. The wax motor is the cold start device. i]ilil/
{R\
.,\'\
\_J
-',lll
/
I
|
ffiml lilil/

S\.-=. l.=ll- /ililil/

il| il/il1

Ir/ E il/ltl
ow iiltilil
l+ p/t
-.U.1 il ln

1//t
It U
la/
W
i 1AH
tat
'gl
"

7, 0n 3-cylinder engines, remove the fuel lift pump,

1, Figure 38, and starter motor, 2, so there is
enough clearance to remove the fuel injection
pump.

B. Remove the accessory drive belt. on 4-cylinder

engines, install a wrench on the tensioner pulley
attaching bolt to remove tension from the belt. on (--/
H.- .\

3-cylinder engines, loosen the alternator mount- -ltl

ing bolts and move the alternator towards the -/- -'
engine to remove tension from the belt. 4-
I
5-.--

2001 2275
i'-_N

21
 ALTERNATIVE METHOD FOR REMOVING THE FUEL INJECTION PUMP
9. On 4-cylinder engines, remove the idler pulley, 1 ,

Figure 39.

, l\: ^<zz,
ll '>-
It '(-/+
I I\..- \ ,il'-
| -JUj-
l'/
fr \Itlt r

53' fi ru

10. Remove fuel injector bleed off line bolts, 1 ,

Figure 40, from the Number 1 and Number 2 fuel

injectors. Discard the two washers on each banjo
bolt.
NOTE: ln sfeps 11 - 25, we will determine the Top
Dead Center (TDC) position of the Number 1 piston,
as well as the engine basic timing position. We will
use the timing pointers listed earlier in the "Special
Tools" section as a reference point and we will mark
the flywheel pulley at the TDC and the basic timing
positions.

40

11 . Remove the Number 1 fuel injector's fuel supply

line and mounting bolts and remove the fuel
injector, 1 , Figure 41 . Discard the cork dust
washer, 2, and copper sealing washer, 3. They
will be replaced later. fltr--tl==--

2001 2259
bb b*'; 41

22
Ehb

|'/lP ALTERNATIVE METHOD FOR REMOVING THE FUEL INJECTION PUMP

12. Install the piston position tool, 1, Figure 42, with
the probe 11 .0 cm below the base, but DO NOT
install the bolts to retain the tool. See Figure 6 for
dimensions of the piston position tool.

13. Remove the fuel injection pump cover, 1, Figure

43. 7 ')^\--'t
-":
y I / L/
--.-.----.,{
l.--,\
\\
{o @t

_*_\_

2001 2261

14. Turn the engine counterclockwise until the piston

Figure 44, indicating the
position tool rises up, 1,
piston is close to Top Dead Center (TDC).

20012277
__l
41

23
 ALTERNATIVE METHOD FOR REMOVING THE FUEL INJECTION PUMP
15. lf you can see the pump mounting bolts, 1 ,
Figure 45, through the holes in the pump drive \ I

gear, 2, the engine is coming up on Top Dead t

Center, compression stroke. lf you cannot see

the bolts, rotate the engine approximately 360
degrees until the tool starts to rise again and the
pump mounting bolts are visible through the drive
gear.

16. Rotate the engine clockwise slightly to allow the

piston position tool to drop back down so that the
base of the tool is flat against the top of the head.

17 . Install two 5/1 6-18 x 1 inch capscrews (PN

9635884) in the piston position tool, Figure 46,
and torque to 22 N'm (17 ft. Ib.).
18. Sfowly rotate the engine counterclockwise until
the piston contacts the tool.

2001 2263

24
 ALTERNATIVE METHOD FOR REMOVING THE FUEL INJECTION PUMP
19. Install the Pointer using the pump cover bolts
holes. Figure 47 shows the 3-cylinder Pointer
installed and Figure 48 shows the 4-cylinder
pointer.

1l
tllt

2?gl 227e
),
47

a
I

,r'----

l
I

iH'-

4B
$,
t

20. Install a 6-inch long piece of tape on the ti

t.
I

I crankshaft pulley, starting 1 inch counterclock- u'*1

wise from the pointer and extending it clockwise,
.;

:
1l

I
Figure 49.
i

25
 ALTERNATIVE METHOD FOR REMOVING THE FUEL INJECTION PUMP
21 . Mark the tape next to the pointer with the piston
against the piston position tool, Figure 50.
e
,f

22. Rotate the engine clockwise slowly almost one

turn until the piston again contacts the tool and
mark the tape next to the pointer, Figure 51 . The
center of these two points is Top Dead Center
(rDC).

2001 2266 l

23. Measure the distance between the two points =_

using a mechanic's ruler. Divide the distance by
__l

==- ___
two and measure this distance from either mark
toward the center. Mark the tape at this point, -
Figure 52.
For example:
Distance between the two points where the
piston hit the piston position tool = 41.0 mm (1 .61
in)
41 .0 mm (1 .61 in) divided by 2= 20.5 mm (0.81
in)
So, you would measure 20.5 mm (0.81 in) from 20012267
one of the points toward the center and mark the
52
tape. This is TDC.

I 26
IP ALTERNATIVE METHOD FOR REMOVING THE FUEL INJECTION PUMP
24. Mark the TDC point on the flywheel pulley with a
punch, Figure 53.
N/z

25. Find the specified distance from TDC to the basic

timing mark on the flywheel pulley from the
"Pump Timing Degree Chart" below. Measure
that distance counterclockwise from the TDC
mark on the pulley, Figure 54. Mark the tape at
this point. This is the engine basic timing before
TDC. Use a punch to mark the pulley, Figure 55.

PUMP TIMING DEGREE CHART. ALTERNATE TIMING METHOD

Distance from TDC to Basic Timing
Cylinder Basic Timing Mark on Flywheel Pulley Pump Lock Degree
3 29 Degrees BTDC 48.6mm +/- 0.1mm 340 Degrees
(1.91 +/- 0.004 in)
4 N/A 29 Degrees BTDC 48.9mm +/-0.1mm 29 Degrees
(1.93 +/- 0.004 in)

26. Remove the piston position tool, install the

injector with a new cork dust gasket (part number
81806277) and a new copper sealing washer
(part number 81 873921 ), and torque the bolts to
22 N.m (17 ft. lb.).

27. Install the fuel bleed off line with a new sealing
/>.1
washer (part number 81867564) above and
below each fitting, and torque the bolts to 13 N.m //
// (/,l/
(1 0 ft. lb.). Tighten the supply tube to the fuel /\
injector to 32 N-m (23 ft. Ibs.). /h\-
\s/ \)
)__
-x-l- (ri,
28. Rotate the engine counterclockwise until the \\ ../
pointer aligns with the basic timing mark. 2001 2274
Remove the top bolt from the pointer and swing \v'a@r
it out of the way.

27
 ALTERNATIVE METHOD FOR REMOVING THE FUEL INJECTION PUMP
29. Remove the pump drive gear nut, 1, Figure 56,
and the washer, 2. Make sure the engine does
not rotate. lf in doubt, install the pointer and make
sure the pointer aligns with the basic timing mark.

1 998301 0

30. Lock the fuel injection pump by loosening the

locking bolt, Figure 57 , moving the locking tab to
the locked position, and torquing the locking
screw to 13 N.m (1 0 ft. lb.). Callout 1 shows the
unlocked position; callout 2 is the locked position.

sMG10013

57
)
31. Install the puller, 1, Figure 58, and break thefuel
injection pump gear away from the tapered pump
shaft.
NOTE: The gear will remain inside the front cover.

28
,MP ALTERNATIVE METHOD FOR REMOVING THE FUEL INJECTION PUMP
32. Remove the pump retaining screws, 1 , Figure
59, by accessing them through theslots in the
pump drive gear,2.

33. Remove the pump and cap all openings so dirt

cannot enter.

The method for lock timing the fuel injection pump is

the same as explained under "lnjection Pump Lock
Timing" earlier in this Tech-Com. In the next section
of this manual, we'll explain how to install the fuel
injection pump on engines where the engine flywheel
timing marks are not accessible or the flywheel does
not have timing marks. To review before going ofl,
answer questions 15 22 in the Dealer-Certified
Technician Test.

iler

il
af

^
5B

29
h*n,