BORLA PERFORMANCE INDUSTRIES 701 Arcturus Ave. Oxnard, Ca. 93033 805-986-8600
2008 BMW 135i Exhaust System Installation
FOR RACING USE ONLY. NOT LEGAL FOR USE ON PUBLIC ROADS.
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 Competition Exhaust System. Borla Performance Competition Exhaust System (Part number 12655) has been designed for the 2008 BMW 135i equipped with a 3.0L 6 cylinder twin turbo engine, rear-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 Competition 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 Competition 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. If you should have any questions regarding installation, or any other matter pertaining to your new Borla Performance Exhaust System, please give us a call at 1-800-GO-BORLA. TITLE: 2008 BMW 135i Installation Instructions PART NO. A-35462 Rev.1 Page 1 of 4
TOOLS: 9 3/8 Drive Ratchet 3/8 Drive Extension 3 15mm Socket 18mm Socket 13mm Socket 8mm Socket 12mm Socket T50 Torx Bit Pry Bar SHOP SUPPLIES: 1 Spray Lubricant
Minimum Required Tool List:
Borla Performance Competition Exhaust System Bill of Materials
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
R/H front pipe assembly L/H front pipe assembly Muffler assembly R/H intermediate pipe L/H intermediate pipe 2.25 clamp (qty 4) Off highway disclaimer Vacuum plug Flat washer (not shown) Bolt M8x70mm (not shown)
TITLE: 2008 BMW 135i Installation Instructions

PART NO. A-35462

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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 Competition 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 Competition 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. 1. Remove the vacuum line from the valve located on the rear of the muffler assembly as shown in figure 1. Insert the vacuum plug provided into the hose and tuck vacuum line into the left rear side panel. Unbolt the flange located just behind the resonator muffler as shown in figure 2. Lubricate all hangers and rubber isolators. Using a muffler stand or an additional person to hold the rear portion of exhaust system up in place, remove the hangers from the rubber isolators and remove the rear muffler from the vehicle as shown in figure 3. Unbolt and remove the center support bracket shown in figure 4 from the vehicle. Place hardware to the side for use during the installation of your new exhaust system. Unbolt and remove the bracket located just in front of the catalytic converters as shown in figure 5. Using a muffler stand or an additional person to hold the remaining exhaust system up in place, unbolt the flanges located in front of the catalytic converters and remove the remaining exhaust from the vehicle as shown in figure 6. Place hardware to the side for use during the installation of your new exhaust system.

Figure 3

Figure 1

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. TITLE: 2008 BMW 135i Installation Instructions PART NO. A-35462

Figure 4

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Borla Performance Competition Exhaust System Installation
1. Using your original hardware, reinstall the center support bracket to the vehicle. 2. Using the original hardware, place the left and right front pipes into position as shown in figure 7. Hand tighten the hardware for now. 3. Using the hardware provided, reinstall the bracket as shown in figure 8 securing the two front pipes. 4. Place a clamp over the expanded ends of the left and right intermediate pipes and set them up into position as shown in figure 9. Do Not tighten the clamps. 5. Place a clamp over the expanded ends of the rear muffler assembly and set it into position as shown in figure 10 making sure to install the hangers into the rubber isolators. Do Not tighten the clamps. 6. Check your exhaust system for proper clearance under the vehicle and also for tip alignment. 7. Once position has been determined to be correct, tighten the Accuseal clamps to 32-35 ft. lbs. and tighten the flange hardware to 18-22 ft. lbs. 8. Before starting your vehicle, make sure to check all wires, hoses, brake lines, body parts and tires for safe clearance from the exhaust system. 9. 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 Competition 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.
Figure 7 Figure 6 Figure 5

Figure 8

Figure 9

Figure 10

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BORLA PERFORMANCE INDUSTRIES 701 Arcturus Ave Oxnard, Ca. 93033 805-986-8600
Exhaust System Installation For 2008 BMW 135i
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 Rear Section Exhaust System. This Borla Performance Rear Section Exhaust System (Part number 11763) has been designed for 2008 BMW 135i equipped with a 3.0L 6 cylinder twin turbo engine, rear 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 BMW 135i Installation Instructions PART NO. A-35458 Page 1 of 4
Minimum Required Tool List: TOOLS: 1 3/8 Drive Ratchet 2 3/8 Drive Extension 14mm Socket 4 Pry Bar SHOP SUPPLIES: 1 Spray Lubricant Borla Performance Rear Section Bill of Materials
1. Muffler assembly 2. Vacuum plug
TITLE: 2008 BMW 135i Installation Instructions

PART NO. A-35458

Page 2 of 4
BORLA PERFORMANCE INDUSTRIES 701 Arcturus Ave Oxnard, Ca. 93033 805-986-8600 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 Rear Section 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 Rear Section 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. Remove the vacuum line from the valve located on the rear of the muffler assembly as shown in figure 1. Insert the vacuum plug provided into the hose. 2. Unbolt the flange located just behind the resonator muffler as shown in figure 2. Place hardware to the side for use during the installation of your new rear section exhaust system. 3. Lubricate hangers and rubber isolators. 4. Using a muffler stand or an additional person to hold the exhaust system in position, remove the hangers from the rubber isolators and remove the rear muffler assembly from the vehicle as shown in figure 3.
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 3 TITLE: 2008 BMW 135i Installation Instructions PART NO. A-35458 Page 3 of 4 Figure 2

Borla Performance Cat-Back Exhaust System Installation
1. Tuck vacuum line into left rear side panel as shown in figure 4. 2. Using your original hardware set the muffler assembly into position as shown in figure 5, making sure to install the hangers into the rubber isolators. Hand tighten hardware for now. 3. Check your exhaust system for proper clearance under the vehicle and also for tip alignment. 4. Once position has been determined to be correct, tighten the flange hardware to 18-20 ft. lbs. Figure 4 5. Before starting your vehicle, make sure to check all wires, hoses, brake lines, body parts and tires for safe clearance from the exhaust system. 6. Start vehicle and check for any leaks. If any leaks are found, determine cause (such as loose hardware) 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.

Figure 5

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