Fel-Pro MS 96116 Exhaust Manifold Gasket Set Instruction Manual

1. Overview

The Fel-Pro MS 96116 Exhaust Manifold Gasket Set is engineered to provide a reliable seal for your vehicle's exhaust manifold. Fel-Pro gaskets are designed for 100% vehicle sealing, utilizing application-specific materials to deliver performance and durability trusted by professionals. This manual provides essential information for proper installation, understanding its function, maintenance, and troubleshooting common issues.

Key Features:

• Meets or exceeds all original equipment specifications.
• Application-specific design ensures a perfect fit.
• Engineered for the sealing repair environment.
• Unsurpassed quality for dependable performance.
• Validated for fit, form, and function.

Image 1.1: Fel-Pro Exhaust Manifold Gasket Set overview.

2. Setup and Installation

Proper installation is crucial for the longevity and performance of your exhaust manifold gasket. Always ensure the engine is cool before beginning any work. Consult your vehicle's service manual for specific torque specifications and procedures.

Safety Precautions:

• Wear appropriate personal protective equipment, including safety glasses and gloves.
• Ensure the vehicle is securely supported on jack stands or a lift.
• Disconnect the battery's negative terminal before starting work.
• Allow the engine to cool completely to prevent burns.

Preparation:

1. Remove the exhaust manifold from the engine, following your vehicle's specific repair procedures.
2. Thoroughly clean both the cylinder head and exhaust manifold mating surfaces. Remove all old gasket material, carbon deposits, and rust. Ensure surfaces are smooth and free of imperfections.
3. Inspect the exhaust manifold for cracks or warpage. Replace if necessary.

Image 2.1: Fel-Pro gaskets are engineered to seal imperfect surfaces, but proper cleaning is still essential.

Installation Steps:

1. Carefully position the new Fel-Pro MS 96116 gasket onto the cylinder head studs or align with the bolt holes. The application-specific design ensures a precise fit.
2. Mount the exhaust manifold onto the cylinder head, ensuring the gasket remains properly seated.
3. Install all manifold bolts or nuts by hand to prevent cross-threading.
4. Tighten the bolts/nuts in the sequence and to the torque specifications provided in your vehicle's service manual. Typically, a multi-stage tightening process is recommended.
5. Reconnect any removed components, such as oxygen sensors, exhaust pipes, and the battery.
6. Start the engine and check for exhaust leaks.

Image 2.2: Slotted bolt holes (where applicable) facilitate easier installation by allowing the gasket to slip into place.

Image 2.3: Professional installation is recommended for optimal results.

3. Function and Performance

The exhaust manifold gasket creates a tight seal between the engine's cylinder head and the exhaust manifold. This seal prevents hot exhaust gases from leaking out, which is critical for maintaining engine performance, fuel efficiency, and proper emissions control. A good seal also prevents exhaust noise and protects surrounding engine components from excessive heat.

Sealing Technology:

• Proprietary Coating: The gasket features an application-specific coating that aids in sealing and makes future removal easier for engine maintenance.
• Blow-Out Resistance: Constructed with high-density fiber-facing material attached to side-specific perforated steel, the gasket is designed to resist blow-out from high-temperature exhaust gases, ensuring a durable seal under extreme conditions.

Image 3.1: The proprietary coating assists in sealing and removal.

Image 3.2: High-density fiber material provides resistance against blow-out from hot exhaust gases.

4. Maintenance

Exhaust manifold gaskets are designed for long-term durability. Regular maintenance primarily involves periodic inspection for signs of wear or leaks. There is no routine maintenance required for the gasket itself once installed correctly.

Inspection:

• Listen for unusual ticking or hissing noises from the engine bay, especially when the engine is cold. These can indicate an exhaust leak.
• Visually inspect the area around the exhaust manifold for black soot stains, which are a clear sign of an exhaust leak.
• If a leak is suspected, it is recommended to have it professionally diagnosed and repaired promptly to prevent further engine damage or performance issues.

5. Troubleshooting Common Issues

If you experience issues after installing or during the lifespan of your exhaust manifold gasket, consider the following common problems and their potential causes.

Exhaust Leaks:

• Symptoms: Ticking or hissing sound from the engine, especially on startup; reduced engine performance; exhaust smell in the cabin; black soot around the manifold.
• Possible Causes: Improper installation (e.g., incorrect torque, uneven tightening, dirty mating surfaces); warped manifold; damaged gasket during installation; prolonged exposure to extreme conditions leading to gasket failure.
• Solution: Re-inspect installation, check manifold for warpage, and replace the gasket if damaged.

Check Engine Light (CEL):

An exhaust leak can sometimes trigger the Check Engine Light. This typically occurs if the leak is upstream of an oxygen sensor, causing the sensor to read incorrect exhaust gas levels. The engine's computer may interpret this as a fault in the emissions system.

• Symptoms: Illuminated Check Engine Light on the dashboard.
• Possible Causes: Exhaust leak affecting oxygen sensor readings.
• Solution: Diagnose the CEL code with an OBD-II scanner. If related to oxygen sensor performance or exhaust system efficiency, inspect for leaks.

Image 5.1: An exhaust leak can sometimes trigger the Check Engine Light.

6. Specifications

7. Warranty Information

For specific warranty details regarding the Fel-Pro MS 96116 Exhaust Manifold Gasket Set, please contact the retailer or seller from whom the product was purchased. Warranty terms and conditions may vary.

8. Support and Contact

If you require further assistance with installation, troubleshooting, or have questions about the Fel-Pro MS 96116 Exhaust Manifold Gasket Set, it is recommended to:

• Consult a certified automotive technician.
• Refer to your vehicle's specific service manual.
• Visit the official Fel-Pro website or their store on Amazon for additional product information and resources: Fel-Pro Store.