BORLA PERFORMANCE INDUSTRIES 701 Arcturus Ave. Oxnard, Ca. 93033 805-986-8600
Exhaust System Installation For 2008 Mini Cooper S Clubman
Precision manufactured using high quality austenitic 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.
Thank you for purchasing a Borla Performance Cat-Back Exhaust System. Borla Performance Cat-Back Exhaust System (Part number 140289) has been designed for the 2008 Mini Cooper S Clubman equipped with a 1.6L Turbocharged 4 cylinder engine, front-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 manufacturers 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 TITLE: 2008 Mini Cooper S Clubman Installation Instructions PART NO. A-35460 Page 1 of 4

TOOLS: 5 6

Minimum Required Tool List:
3/8 Drive Ratchet 3/8 Drive Extension 3 15mm Socket Pry Bar Chain style pipe cutter or reciprocating saw Tape measure SHOP SUPPLIES:
Spray Lubricant Borla Performance Cat-Back Bill of Materials

1. 2. 3. 4. 5. 6. 7.

Front muffler assembly Y pipe assembly R/H rear muffler assembly L/H rear muffler assembly 2.25 clamp 2.00 clamp (qty 2) 2.125 clamp
PART NO. A-35460 Page 2 of 4
TITLE: 2008 Mini Cooper S Clubman Installation Instructions
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.

Figure 1

1. Measure and mark 4 inches ahead of the front muffler as shown in figure 1. 2. Using a reciprocating saw or a chain style pipe cutter, cut the exhaust at the mark as shown in figure 2. Debur inside and outside of the pipe. 3. Unbolt and remove the center support as shown in figure 3. Place the hardware to the side for use during the installation of your new exhaust system. 4. Lubricate all the hangers and rubber isolators. 5. Using a muffler stand or an additional person to hold the exhaust in position, remove the hangers from the rubber isolators and remove the exhaust from the vehicle as shown in figure 4.

Figure 3

Figure 2
Warning: Use extreme caution during installation. Torque all fasteners according to manufacturers 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.

Figure 4 Page 3 of 4

PART NO. A-35460
Borla Performance Cat-Back Exhaust System Installation
1. Place a clamp over the expanded end of the front muffler assembly and set it into position as shown in figure 5. Do Not tighten the clamp. 2. Using the original hardware, install the center support as also shown in figure 5. 3. Place a clamp over the expanded end of the y pipe assembly and set it into position as shown in figure 6. Do Not tighten the clamp. 4. Place a clamp over the expanded end of the left hand rear muffler assembly and set it into position as shown in figure 7 making sure to install hanger into the rubber isolator. Do Not tighten the clamp. 5. Repeat step 4 for the right hand rear muffler assembly. 5. Check your exhaust system for proper clearance under the vehicle and also for tip alignment. 6. Once position has been determined to be correct, tighten the Accuseal clamps to 32-35 ft. lbs. making sure the clamp opening is not over any of the notches in the pipe. 7. Before starting your vehicle, make sure to check all wires, hoses, brake lines, body parts and tires for safe clearance from the exhaust system. 8. 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.
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.
TITLE: 2008 Mini Cooper S Clubman Installation Instructions PART NO. A-35460

Figure 6 Figure 5

Figure 7

Page 4 of 4

Driving Light installation for the MINI Cooper S
These instructions are to be used as a guide only during the installation process. MINI-Madness accepts no responsibility for improper installation of this product. We recommend professional installation if possible.
Note: Standard Cooper Owners, these instructions are identical except for the + - wiring due to the Coopers front battery placement.
Tools needed: Drill bits Power Drill Pop rivet tool available from any autoparts store or home depot for $10-$15 dollars Adjustable wrench Utility knife Black Marker Approximate install time, 3-5 hours depending on mechanical skill
Copyright 2002 MINI-Madness LLC. Distribution or use of this file is expressly forbidden with the exception of MINI-Madness LLC customers for the purposes the MINI Cooper S driving lamp Installation. All rights reserved. 8/29/2002.
Figure 1.1 shows the bracket in its final position. Note its location in relation to the dashed line indicating the black plastic structure of the grill. Flip bracket upside down to mark hole drilling positions as indicates in figure 1.2, 1.3 and 1.4. Fig. 1.1

Fig. 1.2

Mark the lower 2 holes with the black market and prepare for drilling. Repeat this for both sides
To drill for the second brackets It is necessary to remove theblack plastic rib indicated below to fit the extra light bracket This piece is easily removed with the utility knife or a set of needle nose pliers
Drill holes using a sharp drill bit. Select a bit that is the same size as the bracket hole. Fig. 1.5 Note when drilling these 2 holes make sure to go through the plastic layer on top of the metal as the rivet will have to go through this piece as well. Make sure brackets are spaced enough apart to allow adequate space between the lights.
After drilling the 2 lower holes insert bracket into its final position and secure the 2 lower bracket holes with the provided rivets. With the 2 rivets in place drill hole 3 using the bracket hole as your guide as shown in the white circle NOTE: USE CAUTION when drilling the 3rd hole. After you penetrate the metal you need to be careful not to penetrate the hood. Go slow on this one. Secure rivet in hole number 3 and bracket installation is complete Extra rivets are provided in case you mess up installation. If a rivet connection seems to be loose Simply drill out the rivet and reinstall a new one. Fit should be nice and tight.
Run light harness through the hood structure and underneath hood liner. This makes for a clean installation

Fig. 1.9

Run interior switch wires through rubber grommet behind the brake booster. Lift the grommet from the bottom and feed the wires through.
NOTE: For the Cooper simply remove battery cover and attach to the positive battery terminal on the battery itself.
Run main power wire to the battery junction box. Remove nut and attach wire.
Run Negative battery wire to this location and mount to this bolt. Wire should run between these 2 boxes as indicated by the arrow. NOTE: For the Cooper simply remove battery cover and attach to the Negative battery terminal on the battery itself.
Interior With a firm tug and a downward pull, unlatch the knee cover to expose the switch wiring you have pushed through from the engine bay. Tug hard on the cover in a downward motion, its tight.
Pull switch wires through firewall hole to take up any slack. Connect the actual light switch to these wires and mount switch in your desired location.
Mount switch power wire to the yellow and purple as shown below. Mount the Negative black wire to a good ground

fig 2.5

Run switch wires and mount switch. This photo represents one idea for a mounting location