Choose the final configuration before beginning
Borla offers front muffler/resonator 60561 as an optional replacement for the Merge X-Pipe for additional sound control. If that is part of the plan, obtain its own instructions and confirm the complete parts set before removing the original exhaust. This procedure covers the standard 140590 arrangement. Do not assume that an optional component has identical positioning or assembly details simply because it connects within the same exhaust family.
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Remove the original assembly
Loosen both front band clamps. Release their locating pins with a flat screwdriver and slide the clamps aside. Loosen the rear isolator-bracket bolts. With an assistant supporting the exhaust, release the front hangers and slide the assembly rearward, retaining its rear isolators.
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Install loosely, align, then tighten
Return the rear isolators to the vehicle; tighten their bolts to 20 lb-ft. Reuse the front clamps. Fit the X-Pipe and left and right pipe assemblies into the isolators, then attach each muffler with its supplied clamp and rear hanger. Leave clamps loose while setting clearance and tip alignment. Tighten front to rear; Accuseal clamps require 32–35 lb-ft with bolts centered between pipe notches.
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Inspect before and after starting
Check clearance to wiring, hoses, brake lines, bodywork and tires. Start the engine and inspect for leaks; correct loose or misplaced clamps before accepting the installation.
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Avoid the common documentation mistakes
Keep the multi-application instruction sheet open at the steps marked for 140590. The same document covers other engines and layouts, so following the nearest photograph without checking its application is a poor shortcut. Keep removed hardware grouped by location until the final review is complete. Note any unresolved noise, leak or fitment concern in the job record and investigate it; the product’s sound description cannot establish that an individual installation is correct. Keep the original front clamps identified until their reuse is complete.
Products in this guide
Sources / references 2
- Borla installation A-35797 Rev H ↗Reviewed Oct 9, 2026
- Borla 140590 product page ↗Reviewed Oct 9, 2026
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