BORLA Cat-Back 140256 User manual

BORLA PERFORMANCE INDUSTRIES
5901 Edison Dr.
Oxnard, Ca. 93033
805-986-8600
TITLE: 2007-2008 Chevy/GMC 2500/3500
Diesel Installation Instructions PART NO. A-35418 Page 1 of 4
Exhaust System Installation For
2007-2008 Chevy/GMC 2500/3500
Thank you for purchasing a Borla Performance Cat-Back™ Exhaust System.
Borla Performance Cat-Back™ Exhaust System (Part number 140256) has been designed for the
2007-2008 Chevy/GMC 2500/3500 equipped with a 6.6L diesel engine, Crew Cab, Extended Cab or
Regular Cab, Short Bed or Long Bed, two and four-wheel drive and 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.
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.
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
5901 Edison Dr.
Oxnard, Ca. 93033
805-986-8600
TITLE: 2007-2008 Chevy/GMC 2500/3500
Diesel Installation Instructions PART NO. A-35418 Page 2 of 4
Minimum Required Tool List:
TOOLS:
1 3/8” Drive Ratchet
2 3/8” Drive Extension 3”
3 15mm Socket
4 Pry Bar
SHOP SUPPLIES:
1 Spray Lubricant
Borla Performance Cat-Back™ Bill of Materials
1. Front pipe assembly
2. Tail pipe assembly
3. 4.00” clamp
4. Bolt (qty 3)
5. Nut (qty 3)
6. Gasket

BORLA PERFORMANCE INDUSTRIES
5901 Edison Dr.
Oxnard, Ca. 93033
805-986-8600
TITLE: 2007-2008 Chevy/GMC 2500/3500
Diesel Installation Instructions PART NO. A-35418 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. For the removal of your exhaust and installation of your new
exhaust, remove the spare tire as recommended by your
vehicle’s manual.
2. Unbolt the flange shown in figure 1 located just in front of the
muffler.
3. Lubricate all the hangers and rubber isolators.
4. Using a muffler stand or an additional person to hold the exhaust
system into position, remove the hangers from the rubber
isolators and remove the exhaust from the vehicle as shown in
figure 2.
Figure 1
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.

BORLA PERFORMANCE INDUSTRIES
5901 Edison Dr.
Oxnard, Ca. 93033
805-986-8600
TITLE: 2007-2008 Chevy/GMC 2500/3500
Diesel Installation Instructions PART NO. A-35418 Page 4 of 4
Borla Performance Cat-Back 
Exhaust System Installation
1. Using the hardware and gasket supplied with your system, place
the front pipe assembly into position as shown in figure 2 mak-
ing sure to install the hanger into the rubber isolator. Hand
tighten the hardware for now.
2. Place a clamp over the expanded end of tail pipe assembly and
set it into position as shown in figure 3 making sure to install the
hanger into the rubber isolator. Do Not tighten the clamp.
3. Check your exhaust system for proper clearance under the
vehicle and also for tip alignment.
4. Once position has been determined to be correct, tighten the
Accuseal™ clamp to 32-35 ft. lbs. making sure the clamps
openings are not over any of the notches in the pipes.
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 hardware or incorrectly
positioned clamp) and repair as necessary.
7. Install your spare tire as recommended by your vehicle’s manual.
Figure 3
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.
Figure 2