Dorman 635-803 Driver Side Upper Engine Timing Cover Instruction Manual

Product Overview

This manual provides essential information for the Dorman 635-803 Driver Side Upper Engine Timing Cover. This component is a direct replacement part designed to match the fit and function of the original equipment timing cover, ensuring a reliable repair for compatible vehicles.

Image: The Dorman 635-803 Driver Side Upper Engine Timing Cover, a black molded component designed to protect engine timing components.

The Dorman 635-803 timing cover is engineered for durability, specifically designed to withstand the extreme temperatures found under the vehicle's hood, contributing to a long service life. It has undergone extensive quality testing to ensure precise design standards are met, guaranteeing a quality fit and reliable performance.

Vehicle Compatibility

This timing cover is compatible with select Hyundai and Kia models. Please verify fitment for your specific vehicle using the information below:

• Hyundai Santa Fe: 2003, 2004, 2005, 2006
• Hyundai XG350: 2002, 2003, 2004, 2005
• Kia Amanti: 2004, 2005, 2006
• Kia Sedona: 2002, 2003, 2004, 2005

It is crucial to confirm fitment with your vehicle's specific trim before purchase and installation. Refer to your vehicle's service manual for detailed instructions on verifying part compatibility.

Installation Guidelines (Setup)

Installation of the Dorman 635-803 timing cover should be performed by a qualified technician or an individual with appropriate automotive repair experience. Always refer to your vehicle's specific service manual for detailed, step-by-step installation procedures, torque specifications, and safety precautions.

General Steps (Consult Service Manual for Details):

1. Preparation: Ensure the engine is cool and the vehicle is safely supported. Disconnect the battery.
2. Access: Remove any components obstructing access to the existing timing cover (e.g., belts, pulleys, engine mounts, other covers).
3. Removal of Old Cover: Carefully unbolt and remove the old timing cover. Note the position of all fasteners.
4. Surface Preparation: Clean the mating surfaces on the engine block thoroughly, removing all old gasket material and debris. Ensure surfaces are dry and free of oil.
5. Gasket/Seal Installation: Install new gaskets or apply RTV sealant as specified by the vehicle's service manual. Ensure proper alignment.
6. New Cover Installation: Carefully position the Dorman 635-803 timing cover onto the engine. Install all bolts and tighten them to the manufacturer's specified torque sequence and values.
7. Reassembly: Reinstall all previously removed components in reverse order.
8. Final Checks: Reconnect the battery. Check for proper operation and any leaks after initial engine start-up.

Important Safety Note: Working on engine components can be hazardous. Always wear appropriate personal protective equipment (PPE) and follow all safety guidelines. If unsure, seek professional assistance.

Function and Operation

The engine timing cover serves as a protective barrier for critical internal engine components, specifically the timing belt or chain, and associated gears and tensioners. Its primary function is to:

• Protect Components: Shield the timing system from road debris, dirt, moisture, and other contaminants that could cause damage or premature wear.
• Contain Lubricants: Help contain engine oil within the timing area, preventing leaks.
• Maintain Engine Integrity: Contribute to the overall sealed environment of the engine, which is crucial for its efficient operation.

Once properly installed, the Dorman 635-803 timing cover operates passively, providing continuous protection to the engine's timing mechanism throughout the vehicle's operation.

Maintenance and Care

The Dorman 635-803 timing cover is designed for long-term durability and typically requires minimal direct maintenance. However, regular vehicle maintenance practices contribute to its longevity:

• Regular Inspections: During routine vehicle servicing, visually inspect the timing cover for any signs of damage, cracks, or oil leaks.
• Cleanliness: Keep the engine bay clean to prevent excessive dirt and grime buildup on the cover.
• Address Leaks Promptly: If any oil leaks are observed around the timing cover area, have them investigated and repaired by a qualified technician immediately to prevent further damage to the timing components.

This part is designed to be a direct replacement, meaning it should function reliably without specific user maintenance beyond general vehicle care.

Troubleshooting

As a passive protective component, the timing cover itself rarely causes operational issues. Most "troubleshooting" related to a timing cover involves identifying and addressing physical damage or leaks.

For any persistent or severe issues, it is highly recommended to consult a certified automotive technician.

Product Specifications

• Brand: Dorman
• Model: 635-803
• Manufacturer: Dorman Products
• Item Weight: 1.25 pounds
• Product Dimensions: 14 x 12.6 x 4.3 inches
• Position: Upper
• Exterior Finish: Ready To Paint If Needed
• Manufacturer Part Number: 635-803
• OEM Part Numbers: 103183; 502159; 2136039501
• Hollander Number: 308-58950
• ASIN: B003QVJ4G6
• Date First Available: December 1, 2009

Warranty and Support

Dorman Products are engineered for quality and reliability. While specific warranty terms may vary, Dorman stands by its products. For detailed warranty information, please refer to the official Dorman website or contact Dorman customer support directly.

In general, products purchased from Amazon.com are subject to a 30-day return policy. For any product-related inquiries, technical assistance, or to report an issue, please contact Dorman customer service. You can often find contact information on the product packaging or the official Dorman website.

Dorman has over 100 years of experience providing quality automotive replacement parts. Their commitment is to deliver solutions that save time and money, and increase convenience and reliability for repair professionals and vehicle owners.

Image: The Dorman brand logo, representing a century of experience in automotive replacement parts.