Borla 140916 Cat Back Exhaust System Installation Guide

Borla 140916 Cat Back Exhaust System

Installation Guide for Chevrolet Silverado/GMC Sierra 1500 6.2L
PNs 140771, 140772BC/CF, 140773, 140774BC/CF, 140775, 140776BC/CF, 140782, 140783, 140784, 140913, 140914, 140915, 60679, 60680, 60706

• Please compare the parts in the box with the bill of materials provided ***** to ensure 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 completely 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.

Thank you for purchasing a Borla Performance Cat-Back™ exhaust system.

• These Borla Performance Cat-Back™ exhaust systems (PNs 140771, 140772BC/CF, 140773, 140774BC/CF, 140775, 140776BC/CF, 140782,
• 140783, 140784) are designed for the Chevrolet Silverado/GMC Sierra 1500, equipped with a 6.2L V8 engine and 2WD or 4WD automatic transmission.
• These Borla Performance Cat-Back™ exhaust systems (PNs 140913, 140914, and 140915) are designed for the Chevrolet Silverado 1500 ZR2 / GMC Sierra 1500 AT4X, equipped with a 6.2L V8 engine and 4WD automatic transmission.
• Note: PNs 60679 and 60680 are designed only to work with Borla Cat-Back™ PNs 140773, 140774BC/CF, 140775, 140776BC/CF, 140783, 140784, 140914, and 140915. These components are designed to change the sound level of your exhaust system between ATAK and SType.
• They are not compatible with Borla Touring™ Cat-Back system PNs 140771, 140772BC/CF, 140782, and 140913.
• Borla Performance exhaust component PN 60706 is designed only to work with the above Borla Performance Cat-Back™ exhaust systems to adapt them to trucks with a Crew Cab, 6’ 5” bed layout (157” wheelbase). It is not compatible with the stock exhaust.
• 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.

TOOLS

Minimum Required Tool List

1. 3/8” drive ratchet
2. 3/8” drive extension 3”
3. 3/8” drive extension 3”
4. 15mm deep well socket
5. 13mm socket
6. 10mm socket
7. Pry bar

SHOP SUPPLIES

1. Spray lubricant

Borla Performance – Bill of Materials

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 necessary 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 lubricate the threads before attempting to disassemble.

Original Exhaust System Removal

1. Lubricate all hangers, rubber isolators, bolts and nuts.
2. Remove the bolt from the L/H tailpipe hanger mounting bracket (Fig. 1). Keep hardware for later reinstallation.
3. Remove hardware from L/H tailpipe flange near the differential (Fig. 2).
4. Remove L/H tailpipe (Fig. 3).
5. Make a cut directly in front of the muffler assembly (Fig. 4).
6. Loosen hardware on R/H tailpipe hanger mounting bracket and remove (Fig. 5).
7. Using a flathead screwdriver or a pry bar, remove the muffler assembly hangers from their rubber isolators (Figs. 6-7).
8. Using a muffler stand or an additional person, carefully remove the muffler and L/ H tailpipe assembly, bringing it towards the front of the vehicle.
9. Loosen the clamp on the front of the front pipe (Fig. 9). Keep the clamp for later reinstallation.
10. Remove the front pipe from the vehicle.
11. Original exhaust system removed (Fig. 10).

Borla Performance Cat-Back  Exhaust System Installation

1. Orient components on shop floor according to the Borla bill of materials drawing.
2. In order to install the system as shown, we recommend that you connect the Front Pipe Assembly (and PN 60706, if applicable) to the Front Muffler Assembly on the shop floor . This step is not cr itical.
3. Place the original clamp on the inlet of the Front Muffler Assembly and install onto the vehicle (Fig. 11). Do not tighten the clamp. Insert hangers into rubber isolators.
4. S-Type systems only: install the Rear Muffler Assembly (Fig. 12). Refer to this step for PN 60679.
5. ATAK systems only: install the Polyphonic Harmonizer Assembly (Fig. 13). Refer to this step for PN 60680.
6. Install the Y-Pipe Assembly onto the vehicle, connecting it to the Muffler Assembly (Tour ing systems), Rear Muffler Assembly (S-Type systems), or Polyphonic Harmonizer Assembly (ATAK systems) (Fig. 14). Insert hangers into rubber isolators.
7. Reinstall the tailpipe rubber isolators removed during stock removal.
8. Place a clamp on the R/H Tailpipe Assembly then connect it to the Y-Pipe Assembly, inser ting the hanger into its r ubber isolator fir st (Fig. 15). Tailpipe outlet shape may vary from that shown, depending on part number purchased.
9. Place a clamp on the Cross Over Tube and connect it to the Y-Pipe Assembly (Fig. 16). Do not tighten the clamp.
10. Place a clamp on the L/H Tailpipe Assembly and connect it to the Cross Over Tube, inser ting the hanger into its r ubber isolator fir st (Fig. 17). Do not tighten the clamp.
11. 140771, 140773, and 140775 only: Place tailpipe outlets into valance tips (Fig. 18)
12. Check your exhaust system for proper clearance under the vehicle and also for tip alignment. Starting at front flanges and moving to rear of vehicle, tighten flange hardware bolts. Orient position of bolt (on supplied clamps) between (not over) pipe notches and tighten to 35 ft. lbs. torque.
13. Align tips and tighten hardware. Loosen clamps to rotate or slide pipe for better alignment.
14. Before starting your vehicle, make sure to check all wires, hoses, brake lines, body parts and tires for safe clearance from the exhaust system.
15. Start the vehicle and check for any leaks. If any leaks are found, determine cause (such as loose or incorrectly positioned clamp) and repair as necessary.

Borla Performance Cat-Back Exhaust System Installation: 140772BC/CF, 140774BC/CF, 140782, 140783 Quad-Tip Systems

1. Remove the pictured hardware on the L/H and R/H valance tips (Figs. 19, 20, 21).
2. The bolt pictured in Fig. 19 may require an air wrench to remove due to limited clearance.
3. Valance tip removed (Fig. 22).
4. Place a ball clamp on the outlet of the R/H Tailpipe (Fig. 25).
5. Connect the Tip Assembly to the R/H Tailpipe and snug the clamp (Figs. 25-26).
6. Repeat steps 4-5 for L/H Tailpipe / Tip Assembly.
7. Please note that you may rotate and adjust the tip assemblies for optimal fitment.
8. Check your exhaust system for proper clearance under the vehicle and also for tip alignment. Starting at front flanges and moving to rear of vehicle, tighten flange hardware bolts. Orient position of bolt (on supplied clamps) between (not over) pipe notches and tighten to 35 ft. lbs. torque.
9. Align tips and tighten hardware. Loosen clamps to rotate or slide pipe for better alignment.
10. Before starting your vehicle, make sure to check all wires, hoses, brake lines, body parts and tires for safe clearance from the exhaust system.
11. Start the vehicle and check for any leaks. If any leaks are found, determine cause (such as loose or incorrectly positioned clamp) and repair as necessary.

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.

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.

BORLA PERFORMANCE INDUSTRIES

• 500 Borla Drive
• Johnson City TN, 37604-7523
• 805-986-8600

References

• Borla® - Performance Exhaust Systems, Mufflers & Induction

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