Dorman 635-502 Engine Timing Cover Instruction Manual

Dorman 635-502 Engine Timing Cover

Product Specifications:

• Model Number: 635-502
• Product Type: Timing Cover
• Material: Composite Front Cover

Product Usage Instructions

Removal Instructions:

1. Remove the water pump.
2. Remove the crankshaft balancer.
3. Remove the oil pan.
4. Remove the engine shield bolts and shield.
5. Remove the engine wire harness clip from the front cover.
6. Disconnect the crankshaft position (CKP) from the sensor electrical connector.
7. Remove the CKP sensor bolt and sensor.
8. Remove the CKP sensor O-ring seal and discard it.
9. Disconnect the engine wiring harness electrical connector from the camshaft position (CMP) sensor wiring harness jumper.
10. Remove the CMP sensor bolt.
11. Remove the CMP sensor and wiring harness jumper from the engine front cover.
12. Disconnect the CMP sensor wiring harness jumper from the CMP sensor.
13. Remove the CMP sensor from the wiring harness jumper.
14. Remove the front cover bolts.
15. Remove and discard the front cover. Do not reinstall it. Always install a new front cover.
16. Clean all sealing surfaces.

Installation Instructions:

1. Install a new front cover.
2. If reinstalling the old CMP sensor, install a new O-ring seal onto the sensor. Do not reuse the original O-ring seal.
3. Install the CMP sensor to the wiring harness jumper.
4. Connect the CMP sensor wiring harness jumper to the CMP sensor.
5. Lubricate the O-ring seal with clean engine oil.
6. Install the CMP sensor and wiring harness jumper to the engine front cover.
7. Connect the engine wiring harness electrical connector to the CMP sensor wiring harness jumper.
8. Lubricate a new CKP sensor O-ring seal with clean engine oil. Do not reuse the original CKP sensor O-ring seal.
9. Install the new O-ring seal onto the CKP sensor.
10. Install the CKP sensor and bolt. Ensure the CKP sensor is fully seated before tightening the bolt to avoid performance issues or false DTCs.
11. Connect the CKP sensor electrical connector.
12. Install the engine wire harness clip to the front cover.
13. Install the oil pan.
14. Install the crankshaft balancer.

Frequently Asked Questions (FAQ):

Q: Can I reuse the O-ring seals when reinstalling components?
A: No, you should always use new O-ring seals when reinstalling components. Reusing old seals may result in leaks or other issues.

Q: Why is it important to clean all sealing surfaces during removal?
A: Cleaning all sealing surfaces ensures proper sealing and prevents leaks when reinstalling components.

ATTENTION:
Refer to the appropriate shop manual for your vehicle to obtain specific service procedures for this part. If you do not have a service manual or lack the skill to install this part, it is recommended that you seek the services of a qualified technician. Pay special attention to all cautions and warnings included in the shop manual. Read and follow all instructions carefully. This product is only designed to function properly on specific vehicle applications. Please verify that the vehicle requirements match the product specifications and application notes for this part.

REMOVAL/INSTALL OF TIMING COVER (635-502)
Chevrolet 2007–95, GMC 2007–95, Oldsmobile 2001–96, Workhorse 2003–02

PLEASE WEAR
SAFETY GLASSES!

Removal Instructions

STEP 1:
The water pump should be removed.

STEP 2:
The crankshaft balancer should be removed.

STEP 3:
The oil pan should be removed.

STEP 4:
The engine shield bolts and shield should be removed.

STEP 5:
The engine wire harness clip should be removed from the front cover.

STEP 6:
The crankshaft position (CKP) should be disconnected from the sensor electrical connector

STEP 7:
The CKP sensor bolt and sensor should be removed.

STEP 8:
The CKP sensor O-ring seal should be removed and discarded.

STEP 9: The engine wiring harness electrical connector should be disconnected from the camshaft position (CMP) sensor wiring harness jumper.

STEP 10:
The CMP sensor bolt should be removed.

STEP 11:
The CMP sensor and wiring harness jumper should be removed from the engine front cover.

STEP 12:
The CMP sensor wiring harness jumper should be disconnected from the CMP sensor.

STEP 13:
The CMP sensor should be removed from the wiring harness jumper.

STEP 14:
The front cover bolts should be removed.

STEP 15:
The front cover should be removed and discarded. NOTE: Do not reinstall the front cover after the composite front cover is removed. A new front cover should always be installed.

STEP 16:
All sealing surfaces should be cleaned.

Installation Instructions

STEP 1:
A new front cover should be installed.

STEP 2:
The front cover bolts should be installed.

NOTE: The bolts should be tightened to 12 Nm (106 lb·in).

STEP 3: Install a new O-ring seal onto the sensor, if reinstalling the old CMP sensor.

NOTE: The original O-ring seal should not be reused.

STEP 4:
The CMP sensor should be installed to the wiring harness jumper.

STEP 5:
The CMP sensor wiring harness jumper should be connected to the CMP sensor.

STEP 6:
The O-ring seal should be lubricated with clean engine oil.

STEP 7:
The CMP sensor and wiring harness jumper should be installed to the engine front cover.

STEP 8:
The CMP bolt should be installed. NOTE: The bolt should be tightened to 10 Nm (89 lb·in).

STEP 9:
The engine wiring harness electrical connector should be connected from the CMP sensor wiring harness jumper.

STEP 10:
A new CKP sensor O-ring seal should be lubricated with clean engine oil

NOTE: The original CKP sensor O-ring seal should NOT be reused.

STEP 11:
The new O-ring seal should be installed onto the CKP sensor.

STEP 12:
The CKP sensor and bolt should be installed.

NOTE: Make sure the CKP sensor is fully seated before tightening the bolt, when installing the sensor. Erratic performance and false DTCs may result from a poorly seated sensor.

STEP 13:
The CKP sensor electrical connector should be connected.

STEP 14:
The engine wire harness clip should be installed to the front cover.

STEP 15:
The engine shield and bolts should be installed.

NOTE: The bolts should be tightened to 20 Nm (15 lb·ft).

STEP 16:
The oil pan should be installed.

STEP 17:
The crankshaft balancer should be installed.

STEP 18:
The water pump should be installed.

Still need help?
Please call our Technical Support team for assistance from our team of certified automotive experts.
1-800-523-2492

Disclaimer:
Even though every attempt is made to ensure this information is complete and accurate, it is impossible to account for all possible circumstances or situations. Please consult with a qualified auto technician before attempting to perform any work you are not qualified to do. Automobiles can be hazardous to work on; be sure to take all necessary safety precautions. Failure to do so may result in property damage or personal injury. Certain motor vehicle standards and performance requirements may apply to your motor vehicle (such as Federal Motor Vehicle Safety Standards by the National Highway Traffic Safety Administration). Be sure that your work is performed in accordance with such standards and that you do not disable any motor vehicle safety feature.

Dorman Products, Inc.
Corporate Office and Customer Service: 1-800-523-2492 ©2021
No reproduction in whole or in part without prior written approval.

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