Borla 140891 Cat-Back Exhaust System Owner’s Manual

Borla 140891 Cat-Back Exhaust System

Product Information

• Brand: Borla Performance Industries
• Address: 500 Borla Drive, Johnson City TN, 37604-7523
• ContactNumber: 805-986-8600
• Product Name: Borla Performance Cat-BackTMexhaust system
• Compatible Models: – The Kia K5 GT is equipped with a 2.5L inline-4 turbo-charged engine and FWD automatic transmission
• Hyundai Sonata N Line equipped with a 2.5L inline-4 turbo-charged engine and FWD automatic transmission
• Part Numbers: – 140891, 140891BC (for Kia K5 GT) – 140905, 140905BC (for Hyundai Sonata N Line)

Product Usage Instructions

1. Before starting the installation, compare the parts in the box with the provided bill of materials to ensure that you have all the necessary parts.
2.  Read the installation guide completely before beginning the installation of your Borla Performance exhaust system.
3. Visit the Borla website at www.BORLA.com to ensure that the part number you have is compatible with your specific model year.
4. The Borla Performance Cat-BackTM exhaust system PNs 140891, and 140891BC are designed for the Kia K5 GT, while PNs 140905, and 140905BC are designed for the Hyundai Sonata N Line.
5. Tools Required: – 3/8 drive ratchet – 3/8 drive extension – 10mm deep well socket – 15mm deep well socket – 19mm deep well socket – Pry bar
6. Additional Shop Supplies Required: – Spray lubricant
7. For used vehicles, it is recommended to apply a penetrating spray lubricant to all exhaust fasteners and allow sufficient time for the chemical to lubricate the threads before attempting to disassemble.
8. Original Exhaust System Removal:
   • a. Lubricate all hangers, rubber isolators, bolts, and nuts.
   • b. Remove the hardware attaching the driver-side rear muffler assembly to the exhaust assembly.
   • c. Using a flathead screwdriver or pry bar, remove the driver-side rear muffler assembly hangers from the rubber isolator and remove the muffler assembly from the vehicle.
   • d. Remove the hardware connecting the rear exhaust assembly to the front muffler assembly
   •  e. Using a flathead screwdriver or pry bar, remove the rear exhaust assembly hanger from its rubber isolator.
   • f. Using a flathead screwdriver or  pry bar, remove the rear passenger muffler assembly hangers from their rubber isolator and remove the entire exhaust assembly from the vehicle.
   • g. Remove the hardware attaching the panels that cover the under-chassis brace and remove the under-chassis brace.
9. Retain the hardware connecting the front muffler assembly to the vehicle as it will be reused during the installation of your Borla system. Please refer to the user manual for further installation instructions and diagrams

Installation Guide for Kia K5 GT & Hyundai Sonata N Line

PNs: 140891, 140891BC, 140905, 140905BC

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.

• Borla Performance Cat-Back™ exhaust system PNs 140891, and 140891BC are designed for the Kia K5 GT, equipped with a 2.5L inline-4 tur-bo-charged engine and FWD automatic transmission.
• Borla Performance Cat-Back™ exhaust system PNs 140905, and 140905BC are designed for the Hyundai Sonata N Line, equipped with a 2.5L inline-4 turbo-charged engine and FWD automatic transmission.
• 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.

Minimum Required Tool List

TOOLS:

1.  3/8” drive ratchet
2.  3/8” drive extension 6”
3. 10mm deep well socket
4. 15mm deep well socket
5. 19mm deep well socket
6. 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 the 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 ensure 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 allow a significant period of time for the chemical to lubri- cate the threads before attempting to disassemble.

Original Exhaust System Removal

1. Lubricate all hangers, rubber isolators, bolts and nuts.
2. Remove hardware attaching driver side rear muffler assembly to the exhaust assembly (Fig. 1).
3. Using a flathead screwdriver or a prybar, remove the driver side rear muffler assembly hangers from the rubber isolator and remove the muffler assembly from the vehicle (Fig. 2).
4. Remove the hardware connecting the rear exhaust assembly to the front muffler assembly (Fig. 3).
5. Using a flathead screwdriver or a prybar, remove the rear exhaust assembly hanger from its rubber isolator (Fig. 4).
6. Using a flathead screwdriver or a prybar, remove the rear passenger muffler assembly hangers from their rubber isolator and remove the entire exhaust assembly from the vehicle (Fig. 5).
7. Remove the hardware attaching the panels that cover the under chassis brace and remove the under chassis brace (Figs. 6-7).
8. Remove the hardware connecting the front muffler assembly to the vehicle (Fig. 8). This hardware will be reused on the installation of your Borla system.
9. Using a flathead screwdriver or a prybar, remove the front muffler assembly hangers from their rubber isolators and lower the assembly out of the vehicle (Figs. 9-10).
10. The original exhaust system was removed.

Borla Performance Cat-Back  Exhaust System Installation

1. Orient components on the shop floor according to Borla’s bill of materials drawing on page 2.
2. Install the Front Muffler Assembly by mating the flange to the vehicle. Loose-ly tighten the original hardware on the flange and insert the hangers into the original rubber isolators (Figs. 11-12).
3. Place a clamp over the expanded end of the Intermediate Pipe and insert the inlet into the Front Muffler Assembly (Fig. 13). Do not tighten the clamp.
4. Place a clamp over the expanded end of the Y-Pipe Assembly and insert the inlet into the Intermediate Pipe. Insert the hanger into the original rubber isolator (Fig. 14). Do not tighten the clamp.
5. Place a clamp over the rear expanded end of the L/H Rear Muffler Assembly and insert the hangers into the original rubber isolator (Fig. 15). Do not tighten the clamp.
6. Place a clamp over the rear expanded end of the R/H Rear Muffler Assembly and insert the hangers into the original rubber isolator (Fig. 16). Do not tighten the clamp.
7. Once the position has been determined to be correct, tighten the hardware on the Front Pipe Assembly and then tighten the Accuseal clamps to 32-35 ft. lbs (Fig. 17).
8. Not Pictured: Reinstall the original under the chassis brace and covering panels.
9. Before starting your vehicle, make sure to check all wires, hoses, brake lines, body parts, and tires for safe clearance from the exhaust system.
10. Start the vehicle and check for any leaks. If any leaks are found, determine the cause (such as loose or incorrectly positioned clamp) and repair as necessary.

• WARNING : Use extreme caution during installation. Torque all fasteners according to the 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 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 temperatures.

INSTALLATION INSTRUCTIONS
Kia K5 GT & Hyundai Sonata N Line
DOCUMENT ID
A-36067 Rev. A

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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