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5.0L Engine Removal 1. Raise vehicle. Refer to Section 00-02. 2. Disconnect air inlet tube (5F235) from the dual converter and pipe. 3. Remove dual converter and pipe to exhaust manifold retaining nuts. 4. Remove muffler inlet flange to dual converter and pipe outlet flange retaining nuts. 5. Support dual converter and pipe with a suitable jackstand and remove exhaust converter frame bracket to dual converter and pipe retaining nuts. 6. Remove dual converter and pipe from vehicle. 7. Replace any damaged parts. Installation 1. Loosely install dual converter and pipe and support with a suitable jackstand. 2. Install dual converter and pipe onto exhaust converter frame bracket (5E269) and install retaining nuts. Tighten retaining nuts to 14.8-20.2 Nm (11-15 lb-ft). 3. Position dual converter and pipe to exhaust manifold studs and install retaining nuts. Do not tighten nuts. 4. Position muffler inlet flanges to dual converter and pipe outlet flanges and install retaining nuts. Do not tighten nuts. Remove jackstand. 5. Align exhaust system to specification, refer to appropriate illustration. 6. With exhaust system aligned: a. Tighten dual converter and pipe-to-exhaust manifold nuts to 34-46 Nm (25-34 lb-ft). b. Tighten muffler inlet flanges-to-dual converter and pipe outlet flanges retaining nuts to 29.7-40.3 Nm (22-30 lb-ft). 7. Attach air inlet tube to dual converter and pipe. Tighten clamp securely. 8. Check system for leaks and lower vehicle. 3.8L Engine Removal 1. Raise vehicle. Refer to Section 00-02. 2. Remove dual converter and pipe-to-exhaust manifold retaining nuts. 3. Remove dual converter and pipe outlet flange to muffler inlet flange retaining nuts. 4. Support dual converter and pipe with a suitable jackstand and remove exhaust converter frame bracket to dual converter Y pipe retaining nuts. 5. Remove dual converter and pipe from vehicle. 6. Replace any damaged parts. Installation 1. Loosely install dual converter and pipe and support with a suitable jackstand. 2. Install dual converter and pipe onto exhaust converter frame bracket and install retaining nuts. Tighten retaining nuts to 14.8-20.2 Nm (11-15 lb-ft). 3. Position dual converter and pipe to exhaust manifold studs and install retaining nuts. Do not tighten retaining nuts. 4. Position muffler inlet flange to dual converter and pipe outlet flange. Loosely install retaining nuts. 5. Align exhaust system to proper clearance specifications, as shown in the appropriate illustration. 6. With exhaust system aligned: a. Tighten dual converter and pipe to exhaust manifold nuts to 34-46 Nm (25-34 lb-ft). b. Tighten muffler inlet flange to dual converter and pipe flange retaining nuts to 29.7-40.3 Nm (22-30 lb-ft). 7. Check exhaust system for leaks.

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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. Using a reciprocating saw or a hacksaw, cut the stock tailpipe just after the forward muffler/front pipe assembly as shown in figure 1. Apply a sparing amount of spray lubricant to each rubber mount/hanger assembly such as the one shown in figure 2, then remove the two rear hangers from the rubber mounts and pull rear tailpipe/muffler assembly from vehicle. Remove the two bolts securing the flange of the muffler/front pipe assembly to the catalytic converter. Remove all hangers from the rubber mounts and pull the muffler/front pipe assembly from the vehicle. Figure 1 Figure 2 You are now ready for the installation of your Borla Performance Cat-Back™ 1. 2. Place your new Borla Performance front pipe assembly onto the vehicles flange. Push the two hangers into the rubber mounts and place the two bolts, nuts and washers provided into the flange as shown in figure 3. DO NOT tighten the two bolts at this time. Place a clamp over the expanded end of the muffler assembly, then place the muffler assembly onto the front pipe assembly as shown in figure 4, push the two hangers into the rubber mounts. DO NOT tighten the clamp. Place a clamp on the expanded end of the tailpipe assembly and push the two hangers into the rubber mounts. DO NOT tighten the clamp. Check your exhaust system for proper clearance under the vehicle and also for tip alignment. Once position has been determined to be correct, tighten the two Accuseal™ clamps between 32- 35 ft. lbs. and the two bolts securing the front pipe to the flange. Before starting your vehicle, make sure to check all wires, hoses, brake lines, body parts and tires for safe clearance from the exhaust system. Start vehicle and check for any leaks. If any leaks are found, determine cause (such as loose or 3. 4. 5. 6. 7. 8.

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1. Prepare for Installation. (a) Verify kit contents (b) Wear safety glasses. (c) Raise vehicle. (d) Caution muffler might be hot NOTE: Apply masking tape to quarter panels above the bumper fascia. To prevent damage when removing the bumper fascia, apply masking tape on the underside of the bottom left- hand corner of the door and left hand upper corner of door. (Fig. 1-1) 2. Prepare Vehicle for Rear Bumper Fascia Removal. (a) Open rear door (Fig. 2-1). (b) Protect exhaust tip with a rag or protective tape during installation of hitch. (Fig. 2-1) NOTE: If the vehicle is equipped with proximity sensors, detach the sensor wire connector from inside the fascia, behind the rear wheels on both sides of the vehicle (Fig. 2-2). 3. Remove Rear Bumper Fascia. NOTE: Protect rear bumper to prevent damage from tools (i.e. air tools) when removing the fascia bolts. (a) Remove the 13 6 mm hex head bolts (A) from rear bumper fascia. (Fig. 3-1) (b) Remove one (1) push pin (B) from fascia (Fig. 3-1) (c) Unsnap the sides of the fascia from the vehicle. (Fig. 3-2) (d) With one person on each end, remove fascia from vehicle. Store in a safe place to avoid damage during installation. (Fig. 3-2) 4. Install Hitch. (a) Install one (1) M12 x 45 bolt into the 13 mm hole as shown (Bolt 1). (Fig. 4-1) (b) Install two (2) M12 x 45 bolts in the lower slots (Bolts 2 & 3). (Fig. 4-1) (c) Install three (3) M12 x 45 bolts in the 15mm holes (Bolts 4 to 6). (Fig. 4-1)

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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. The OE exhaust cannot be removed without cutting the pipe above the rear-axel area. Cut pipe as indicated using a metal-cutting blade (Figure 1). Support the muffler as needed while cutting. 2. Loosen the (2) clamp bolts as shown (13mm) and slide clamp towards front of vehicle. (Figure.2) 3. Using a muffler stand or an additional person to hold the muffler assem- bly up into position, slide the (2) hangars out of the rubber isolators and remove the front muffler assembly. Keep the hardware for use during the installation of your new exhaust system. (Figure 3) 4. Slide the (2) hangars out of the rubber isolators and remove the rear muf- fler assembly. Warning: Use extreme caution during installation. Torque all fasteners according to 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. TITLE: 2009-2010 Volkswagen Jetta TDI Sedan and Sport Wagon TDI Installation Instructions (pn-140317)

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Note: This system is designed to use the stock hanger locations. Please check the alignment of your OEM system before installation. If the tips of your OEM system are not straight or centered in the rear valance, then the replacement system will also be misaligned. Removal of the O.E.M. system: 1. Park the vehicle on a smooth level asphalt or concrete surface and set the parking brake firmly. Place a block in front of and behind the front wheels. Jack up the rear of the vehicle and place on jack stands under the frame in the manufactures specified locations. Alternatively, it would be best to have the vehicle raised on a hydraulic lift. Warning: Do not work under a vehicle being held up by only a jack. Place jack stands securely under the vehicle in the manufacture-specified location. 2. Spray all the rubber hangers with a spray lubricant to ease removal of the system. See (Fig.1) 3. Remove the 2 nuts at the flange. Pull the muffler out of the hangers. See (Fig.2) 4. Next you will be removing the black cover covering the bumper in order to make the cutout for the exhaust tip. You will be removing various screws holding it on from underneath/backside of the bumper. See (Fig.3) 5. Unbolt the reflectors by removing the screw holding them on. This will be needed in order to gain access to the 2 inner screws holding on the black cover. Figure 4 See (Fig.4) They easily pop off once the screw has been removed. Set aside carefully. 6. When the reflector has been removed you will need to unscrew the upper portion of the black bumper cover where shown in (Fig.5) There is 1 screw holding each corner of the upper black cover. Set aside as they will be reused. Figure 5