Borla 140857-BC-CF Performance Cat Back Exhaust System Installation Guide

Borla 140857-BC-CF Performance Cat Back Exhaust System

Product Information

Product Usage Instructions

Please follow the instructions below for the installation of your Borla Performance exhaust system on your Chevrolet Tahoe 5.3L & 6.2L:

1. Compare the parts in the box with the bill of materials provided to ensure you have all the necessary parts for installation.
2. Lubricate all hangers, rubber isolators, bolts, and nuts with a spray lubricant.
3. Lower and remove the spare tire and remove the hardware connecting the heatshield to the vehicle.
4. Loosen and remove the hardware that connects the tailpipes to the muffler assembly.
5. Remove the hardware that connects the rear sway bar to the vehicle and let the sway bar hang.
6. Loosen the clamp that connects the exhaust to the vehicle. This clamp will be reused for the installation of your Borla System.
7. Using a flathead screwdriver or a prybar, remove the muffler assembly hangers from the rubber isolators.
8. Rotate the muffler to clear the rear axle and sway bar, then slide the assembly toward the front of the vehicle to begin the removal of the original muffler assembly.

Note: If you are installing this exhaust system on a used vehicle, it is recommended to apply a penetrating spray lubricant liberally to all exhaust fasteners and allow sufficient time for the chemical to lubricate the threads before attempting to disassemble.

***** 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 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 systems PNs 140856/BC/CF, 140857/BC/CF are designed for the Chevrolet Tahoe equipped with a 5.3L V8 engine and 2WD or 4WD automatic transmission. Borla Performance Cat-Back™ exhaust systems PNs 140858/BC/CF, 140859/BC/CF are designed for the Chevrolet Tahoe equipped with a 6.2L V8 engine and 2WD or 4WD 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.

TOOLS

Minimum Required Tool List:

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

SHOP SUPPLIES:

1. Spray lubricant

PARTS DESCRIPTION

INSTALLATION

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 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. Lower and remove the spare tire and remove the hardware connecting the heatshield to the vehicle (Fig. 1).
3. Loosen and remove the hardware that connects the tailpipes to the muffler assembly (Figs. 2-3).
4. Remove the hardware that connects the rear sway bar to the vehicle and let the sway bar hang (Fig. 4).
5. Loosen the clamp that connects the exhaust to the vehicle (Fig. 5). You will be reusing this clamp to install your Borla System.
6. Using a flathead screwdriver or a prybar, remove the muffler assembly hangers from the rubber isolators (Figs. 5-6).
7. Begin removal of the original muffler assembly by rotating the muffler to clear the rear axle and sway bar and slide the assembly toward the front of the vehicle (Fig. 7).
8. Using a muffler stand or an additional person, carefully remove the original muffler assembly by lowering it through the gap between the vehicle and the sway bar (Fig. 8).
9. Remove the tailpipe hangers from their rubber isolators by pushing the assembly up and over the rear axle toward the front of the vehicle (Fig. 9).
10. Remove the tailpipe assembly by angling the tip section toward the ground and lowering the assembly out from the rear of the vehicle (Fig. 10).
11. Remove the front clamp to be used on your Borla system by using a flathead screwdriver or a prybar to open the clip that locates them (Fig. 11).
12. Original exhaust system removed.

Borla Performance Cat-Back Exhaust System Installation

1. Orient components on shop floor according to Borla bill of materials drawing on.
2. Install Front Pipe Assembly using the original clamp. Insert the hanger into the original rubber isolator (Fig. 12). Do not tighten the clamp.
3. Place a clamp over the expanded end of the Muffler Assembly and insert the inlet to the Front Pipe Assembly (Fig. 13). Do not tighten the clamp.
4. Reinstall the sway bar to the vehicle and move the Y-Pipe Assembly onto the vehicle by inserting it up and over the rear axle (Fig. 14).
5. Place a clamp over the expanded end of the Y-Pipe Assembly and insert the inlet to the Muffler Assembly. Insert the hangers into the original rubber isolators (Fig. 15). Do not tighten the clamp.
6. Place a clamp over the expanded end of the R/H Tailpipe Assembly and insert the inlet to the Y-Pipe Assembly. Insert the hanger into the original rubber isolator (Fig. 16). Do not tighten the clamp.
7. Place a clamp over the expanded end of the Cross-Over Pipe and insert the inlet to the Y-Pipe Assembly (Fig. 17). Do not tighten the clamp.
8. Place a clamp over the expanded end of the L/H Tailpipe Assembly and insert the inlet to the Cross-Over Pipe. Insert the hanger into the original rubber isolator (Fig. 18). Do not tighten the clamp.
9. Place a clamp over each expanded end of the L/H & R/H Tip Assemblies and insert the inlet to the L/H & R/H Tailpipe Assemblies (Fig. 19). Do not tighten the clamps.
10. Once the position has been determined to be correct, tighten the Accuseal clamps to 32-35 ft. lbs.
11. Reinstall the heatshield and spare tire.
12. Before starting your vehicle, make sure to check all wires, hoses, brake lines, body parts and tires for safe clearance from the exhaust system.
13. 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 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 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

Read User Manual Online (PDF format)

Download This Manual (PDF format)

Download this manual  >>