BORLA 140317 User manual

BORLA PERFORMANCE INDUSTRIES
TITLE: 2009-2010 Volkswagen Jetta TDI
Sedan and Sport Wagon TDI Installation
Instructions (pn-140317)
PART NO. A-35503 Rev. 1 Page 1 of 4
Exhaust System Installation For
2010 Volkswagen Jetta TDI
Thank you for purchasing a Borla Performance Exhaust System.
This Borla Performance Cat-Back™ Exhaust System (Part number 140317) has been designed for the
2009-2010 Volkswagen Jetta TDI Sedan & Sport Wagon equipped with a 2.0L 4-cylinder diesel engine,
automatic or manual transmissions.
Borla Performance Industries recommends that an exhaust shop or professional after market parts installer, who has all the necessary
equipment, tools and experienced personnel needed for proper installation, should perform the installation of this system. However,
if you decide to perform the installation, we recommend someone should help you. Ensure the installer uses 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.
Precision manufactured using aircraft quality T-304 stainless steel; this system is designed to endure years of heavy use. Installing
a Borla Performance Exhaust System on your vehicle will eliminate the restrictive design of the stock exhaust, allowing your
engine to discharge exhaust gas easier. The result is more horsepower and torque, longer engine life, and a distinctive throaty
growl- all this, with easy bolt-on installation. These installation instructions have been written to help you in the installation of
your Borla Performance Exhaust System. Please read it completely before installing your system.

BORLA PERFORMANCE INDUSTRIES
TITLE: 2009-2010 Volkswagen Jetta TDI
Sedan and Sport Wagon TDI Installation
Instructions (pn-140317)
PART NO. A-35503 Rev. 1 Page 2 of 4
Minimum Required Tool List:
TOOLS:
1 3/8” Drive Ratchet
2 3/8” Drive Extension 3”
3 13mm Socket
4 Metal cutting sawsall
5 Pry Bar
SHOP SUPPLIES:
1 Spray Lubricant
Borla Performance Cat-Back™ Bill of Materials
1. Front pipe assembly
2. Tail Pipe assembly
3. 2.50” clamp (qty 1)
1
2
3

BORLA PERFORMANCE INDUSTRIES
TITLE: 2009-2010 Volkswagen Jetta TDI
Sedan and Sport Wagon TDI Installation
Instructions (pn-140317)
PART NO. A-35503 Rev. 1 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
Cat-Back™ 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 necessary for the installation of your new Borla
Performance Cat-Back™ Exhaust System.
Original Exhaust System Removal
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 lubricate the threads before attempting to
disassemble.
1. The OE exhaust cannot be removed without cutting the pipe above the
rear-axel area. Cut pipe as indicated using a metal-cutting blade (Figure
1). Support the muffler as needed while cutting.
2. Loosen the (2) clamp bolts as shown (13mm) and slide clamp towards
front of vehicle. (Figure.2)
3. Using a muffler stand or an additional person to hold the muffler assem-
bly up into position, slide the (2) hangars out of the rubber isolators and
remove the front muffler assembly. Keep the hardware for use during the
installation of your new exhaust system. (Figure 3)
4. Slide the (2) hangars out of the rubber isolators and remove the rear muf-
fler assembly.
Warning: Use extreme caution during installation. Torque all fasteners
according to manufacturer’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.
Figure 1
Figure 2
Figure 3

BORLA PERFORMANCE INDUSTRIES
TITLE: 2009-2010 Volkswagen Jetta TDI
Sedan and Sport Wagon TDI Installation
Instructions (pn-140317)
PART NO. A-35503 Rev. 1 Page 4 of 4
Borla Performance Cat-Back Exhaust
System Installation
1. Familiarize yourself and position old and new parts as shown. This will
aide in the installation. (Figure 4)
2. Position the front pipe assembly and insert your new exhaust pipe into
the OE pipe. Connect the (2) hangars into the OE rubber isolators.
(Figure 5) Slide and position the clamp with the bolts accessible to
tighten. DO NOT tighten these bolts.
3. Place the Accuseal clamp over the tailpipe assembly and slide this pipe
over the front muffler assembly pipe. Connect the (2) hangars into the
OE rubber isolators. Slide the Accuseal clamp over the notches and ro-
tate the clamp-bolt 90-degress from the notches. The clamp-bolt should
be positioned between the notches. (Figure 6) Do not tighten tighten this
bolt. NOTE: When properly clamped, the Accuseal pipe closes in a
circular-shape with interlocking notches creating a proper seal. The
pipe will distort or ovalize in shape if the clamp-bolt is positioned over
the notches.
4. Check your exhaust system for proper clearance under the vehicle and
also for tip alignment. (Figure 7) Once position has been determined to
be correct, tighten the Accuseal™ clamp 32-35 ft. lbs. Tighten the OE
clamp bolts.
5. Before starting your vehicle, make sure to check all wires, hoses, brake
lines, body parts and tires for safe clearance from the exhaust system.
6. Start vehicle and check for any leaks. If any leaks are found, determine
cause (such as loose or incorrectly positioned clamp) and repair as
necessary.
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 coating
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
temperatures.
Congratulations!!! You have completed the installation of the
world famous Borla Performance Stainless Steel Exhaust System.
Figure 5
Figure 7
Figure 6
Figure 4