BORLA 140597 User manual

BORLA PERFORMANCE INDUSTRIES
500 Borla Drive
Johnson City TN, 37604-7523
805-986-8600
DOCUMENT PART NUMBER
A-35805 Rev. B
INSTALLATION INSTRUCTIONS
Volkswagen Golf GTI
PAGE
1 of 4
Exhaust System Installation for VW Golf GTI
PN-140597
Thank you for purchasing a Borla Performance Exhaust System.
Borla Performance Cat-Back™ Exhaust System (PN-140597) is designed for the
Volkswagen Golf GTI equipped with a 2.0T 4-cylinder turbo engine, automatic or manu-
al transmissions.
Borla Performance Industries recommends that an exhaust shop or professional after market parts installer perform the installation of this system.
However, if you decide to perform the installation on your own it is recommended that two people are used. This installation should not be per-
formed by one person due to the risk of injury. Ensure the installers use all under car safety precautions including eye protection.
Please take time to read and understand the following…
By installing your Borla Performance Exhaust System, you indicate that you have read this document and you agree with the terms stated below.
It is the responsibility of the purchaser to follow all installation instruction guidelines and safety procedures supplied with your Borla Performance
Exhaust System.
Borla Performance Industries assumes no responsibility for damages occurring from misuse, abuse, improper installation, improper operation, lack
of responsible care, or all previously stated reasons resulting from incompatibility with other manufacturer’s products and/or systems.
Included with your Borla Performance Exhaust System is a warranty card. Please read it carefully before you begin any work on your vehicle. If
you should have any questions regarding our warranty policy, installation, or any other matter pertaining to your new Borla Performance Exhaust
System, please give us a call at the number provided on the warranty card.
***** Please compare the parts in the box with the bill of materials provided *****
to assure that you have all the parts necessary for this installation.
These instructions have been written to help you with the installation of your Borla Performance Exhaust System. Please read this document com-
pletely before beginning the installation of your system.
To ensure this part number fits your specific model year, please visit our website for the latest model year listings at www.BORLA.com

BORLA PERFORMANCE INDUSTRIES
500 Borla Drive
Johnson City TN, 37604-7523
805-986-8600
DOCUMENT PART NUMBER
A-35805 Rev. B
INSTALLATION INSTRUCTIONS
Volkswagen Golf GTI
PAGE
2 of 4
140597
Minimum Required Tool List:
TOOLS:
13/8” Drive Ratchet
23/8” Drive Extension 3”
313mm Socket
415 mm Socket
516mm Socket
5 Pry Bar
SHOP SUPPLIES:
1Spray Lubricant
Borla Performance Bill of Materials

BORLA PERFORMANCE INDUSTRIES
500 Borla Drive
Johnson City TN, 37604-7523
805-986-8600
DOCUMENT PART NUMBER
A-35805 Rev. B
INSTALLATION INSTRUCTIONS
Volkswagen Golf GTI
PAGE
3 of 4
Caution!!! Never work on a hot exhaust system. Serious injury in the form of burns can result If the vehicle
has been in use and the exhaust system is hot, allow vehicle to cool for at least 1 hour. Always wear eye
protection when working under any vehicle.
Note: It is our recommendation that you use a hoist or hydraulic lift to facilitate the installation of your new
Borla Performance Exhaust System.
Taking all under car safety precautions, lift the vehicle using a hoist or hydraulic lift. Once this has been
done, you may begin the removal of your old exhaust system from your vehicle.
Note: Before removing the original exhaust system from your vehicle, please compare the parts you have
received with the bill of materials provided on the previous page to assure that you have all the parts neces-
sary for the installation of your new Borla Performance Exhaust System.
Note: With a used vehicle, we suggest a penetrating spray lubricant to be applied liberally
to all exhaust fasteners and allowing a significant period of time for the chemical to lubri-
cate the threads before attempting to disassemble.
Original Exhaust System Removal
1. Loosen the (2) clamp bolts as shown (13mm) and slide clamp to-
wards front of vehicle. (See Fig.1)
2. Using a muffler stand or an additional person to hold the muffler
assembly up into position, slide the (5) hangars out of the rubber iso-
lators and remove the system from the rear. (See Fig. 2) Keep the
hardware for use during the installation of your new exhaust system.
3. Exhaust system removed. (See Fig. 3)
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2
3

BORLA PERFORMANCE INDUSTRIES
500 Borla Drive
Johnson City TN, 37604-7523
805-986-8600
DOCUMENT PART NUMBER
A-35805 Rev. B
INSTALLATION INSTRUCTIONS
Volkswagen Golf GTI
PAGE
4 of 4
NOTE: When you first start your vehicle after the installation of your new Borla Performance Exhaust
System, there may be some smoke and fumes coming from the system. This is a protective oil based coat-
ing used in the manufacturing of mandrel bent performance exhaust tubing. This is not a problem and
will disappear within a very short period of time after the exhaust has reached normal operating temper-
atures.
WARNING: Use extreme caution during installation. Torque all fasteners according to manufactur-
er’s torque values and tightening sequence. DO NOT use air impact tools to tighten fasteners on
Borla Performance Exhaust Systems. Use of such tools may result in bent flanges or gasket contact
areas leading to exhaust leaks.
Borla Performance Cat-Back 
Exhaust System Installation
1. Insert the Front Pipe into the OE band clamp. Slide and position the clamp
with the bolts accessible to tighten later. Do not tighten these bolts.
2. Place a 2.50” Accuseal clamp over the Muffler Assembly and insert into
the Front Pipe. Insert hanger into rubber isolators.
3. Place the 2.50” Accuseal clamp over the Y-Pipe Assembly and insert inlet
into the Muffler Assembly. Insert hanger into rubber isolators. (See Fig. 4)
4. Place a 2.00” Accuseal clamp over the L/H Tail Pipe Assembly and insert
inlet into the Y-Pipe Assembly. Insert hanger into rubber isolators. (See
Fig. 5)
5. Slide the Accuseal clamp over the notches and rotate the clamp-bolt 90-
degress from the notches. The clamp-bolt should be positioned between the
notches. (See Fig. 6) Do not tighten tighten this bolt. NOTE: When
properly clamped, the Accuseal pipe closes in a circular-shape with inter-
locking notches creating a proper seal. The pipe will distort or ovalize in
shape if the clamp-bolt is positioned over the notches.
6. Check your exhaust system for proper clearance under the vehicle and also
for tip alignment. Once position has been determined to be correct, tighten
the Accuseal™ clamp 32-35 ft. lbs. Tighten the OE clamp bolts. (See Fig.
7)
7. Start vehicle and check for any leaks. If any leaks are found, determine
cause (such as loose or incorrectly positioned clamp) and repair as neces-
sary.
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