Land Cruiser 200 Series Mods: Upgrading to Borla S-Type Exhaust for 30 Extra Horsepower

The Toyota Land Cruiser 200 Series is one of the most capable and durable SUVs ever built, renowned for its off-road prowess and legendary reliability. However, even the best factory-engineered vehicles leave room for improvement. For owners seeking to unlock hidden performance, the exhaust system is a prime upgrade target. The Borla S-Type cat-back exhaust system stands out as a top-tier modification, delivering a claimed increase of up to 30 horsepower and a more aggressive exhaust note. At roughly $1,800, this modification represents a significant investment, but one that can transform the driving experience both on and off pavement.

This article provides a detailed, technical breakdown of the Borla S-Type exhaust for the Land Cruiser 200 Series: what it is, how it performs, installation considerations, cost analysis, and how it fits into a broader build strategy. Whether you're planning a DIY install or sourcing your parts through a platform like Fleet, this guide will help you make an informed decision.

Why Upgrade the Exhaust on a Land Cruiser 200?

The stock exhaust system on the 200 Series is designed for quiet operation, emissions compliance, and low manufacturing cost. It features crushed bends, restrictive mufflers, and relatively small-diameter tubing. These compromises restrict exhaust flow, especially when the engine is working hard under load or at high RPM. By replacing the entire cat-back system, you address two critical goals: reducing backpressure and enhancing scavenging.

Improved exhaust flow allows the 5.7L V8 (and earlier 4.7L or diesel variants) to breathe more freely. This directly translates to gains in horsepower and torque, particularly in the mid-to-upper RPM range where the engine's power band is strongest. Additionally, the factory exhaust is heavy—the Borla S-Type uses T-304 stainless steel that is both lighter and more durable than the OEM mild steel.

Key Benefits Beyond Horsepower

  • Weight reduction: The Borla system saves approximately 20–25 pounds compared to the stock setup, contributing to improved acceleration and fuel economy.
  • Enhanced sound: The S-Type delivers a deep, aggressive growl without being overly loud or drone-prone at highway speeds.
  • Heat management: Mandrel-bent tubing and expanded internal volume reduce exhaust gas temperature, which can help underhood components last longer.
  • Towing advantage: More torque at lower RPMs means easier towing of heavy trailers, a common use case for the Land Cruiser.

Overview of the Borla S-Type Exhaust System

Borla offers multiple performance exhaust lines, but the S-Type is their most popular for full-size SUVs and trucks. It is a cat-back system, meaning it replaces everything from the catalytic converters rearward. This is a bolt-on modification that does not require tuning (though tuning can optimize the gains).

Construction and Materials

  • Material: T-304 stainless steel (austenitic, highly corrosion-resistant)
  • Tubing: 3-inch mandrel-bent (no crimping, maintaining full diameter through bends)
  • Mufflers: Straight-through, high-flow with internal packing and resonator
  • Tips: Polished stainless steel, dual-wall design (available in dual split or single tailpipe configurations)
  • Warranty: Limited lifetime (covers defects, not rust-through in road-salt states)

The S-Type is distinguished from Borla's Touring (quieter) and Atak (louder) lines by its balance of sound output—more aggressive than stock but still civilized for daily driving.

Compatibility Notes

The Land Cruiser 200 Series (model years 2008–2021) shares its chassis with the Lexus LX 570. The Borla S-Type cat-back is designed to fit both vehicles without modification. However, be aware that some aftermarket bumpers, rear air suspension, or underbody skid plates may interfere with the exhaust routing. Always verify clearance before purchase.

Installation Process: Step-by-Step Guide

Installing the Borla S-Type exhaust is a moderate DIY job that takes 2–4 hours with standard tools. Professional installation typically costs $200–$500, but many enthusiasts choose to do it themselves to save money and learn about their vehicle.

Tools Needed

  • Floor jack and jack stands (or lift)
  • Socket set (10mm to 19mm) and ratchet
  • Wrenches (combination, 10mm–19mm)
  • WD-40 or penetrating oil (for stubborn bolts)
  • Oil filter wrench (to remove stock exhaust hangers)
  • Exhaust hanger removal tool (optional but helpful)
  • Torque wrench (for final tightening)

Procedure Overview

1. Preparation – Safely raise the vehicle, ensuring it is level. Note the routing of the stock exhaust, including the O2 sensor wiring and any heat shields that may need temporary removal.

2. Remove the factory exhaust – Starting at the rear, unbolt the hangers, separate the clamps, and lower the muffler. Work forward to remove the intermediate pipe and Y-pipe section. On some 200 Series models, the spare tire needs to be dropped or removed for clearance.

3. Transfer components – Reuse the factory gaskets (or replace with new ones if supplied). If your Land Cruiser has secondary catalytic converters (pre-2013 models), ensure the Borla system does not require their removal—it should bolt directly after the primary cats.

4. Install the Borla system – Begin at the front, loosely attaching each section with the provided clamps. Work your way rearward, ensuring the pipes do not contact the frame, body, or driveline. Borla includes detailed instructions; follow their suggested order.

5. Align and tighten – With all joints loosely fitted, adjust the exhaust tips to be centered in the rear bumper cutouts. Then tighten all clamps to the specified torque (usually 30–40 ft-lbs).

6. Check for leaks – Start the engine and inspect all connections for exhaust leaks. A small leak can cause a tick or hiss. Tighten as needed.

Common Installation Challenges

  • Stuck bolts: Use penetrating oil and patience. Rear hanger bolts are prone to corrosion.
  • Rub on sway bar: On some 200 Series, the intermediate pipe may contact the rear sway bar. A small spacer or heat shield can fix it.
  • Tip alignment: If the tips are not centered, loosen clamps and twist the muffler section slightly.

For a detailed video guide, check out Borla's official installation videos or search for "Borla S-Type Land Cruiser 200 install" on YouTube.

Performance Gains: What 30 Horsepower Means for the 200 Series

Borla's advertised 30-horsepower increase is a peak figure, typically achieved at high RPM (around 5,000–5,500 RPM). In real-world driving, you will feel a broader powerband with noticeable gains from 2,500 RPM upward. The 5.7L 3UR-FE V8 makes 381 horsepower stock; the Borla S-Type pushes it to around 410–415 at the crank (a ~7% increase). Torque gains are smaller but still significant—about 20–25 lb-ft at the peak.

Independent dyno tests on the Land Cruiser 200 validate these claims. For example, IH8MUD forum members have reported gains of 28–32 horsepower on a chassis dyno when combined with a cold air intake and tune. The exhaust alone is worth 15–20 wheel horsepower.

Driving Experience Improvements

  • Smoother acceleration: The engine revs more freely, especially when passing or merging onto highways.
  • Improved throttle response: Less exhaust restriction means the engine responds more quickly to pedal input.
  • Enhanced towing: At 3,000–4,000 RPM (typical towing range), torque is up by 15–20 lb-ft, making hill climbs less strain on the transmission.
  • Sound quality: The S-Type's note is deep and purposeful without being obnoxious. No drone at cruising speeds, a common complaint with cheaper systems.

Cost Analysis: Is $1,800 Worth It?

At $1,800 MSRP (often found for $1,500–$1,700 on discount), the Borla S-Type is not cheap. However, when you consider the quality of materials, lifetime warranty, and the fact that it replaces multiple OEM components, the cost is justified for many Land Cruiser owners.

Breakdown of Total Investment

ItemCost
Borla S-Type cat-back exhaust (part #140867 or similar)$1,800
Professional installation (average rate $100/hr, 2–4 hours)$200–$500
Optional: new gaskets, O2 sensor (if accidentally damaged)$30–$100
Total typical cost$2,030–$2,400

If you DIY, your total is just the cost of the exhaust plus maybe a few dollars for penetrating oil. That makes it a more attractive proposition.

Value Proposition Compared to Other Mods

For $1,800, you might also consider a tune ($400–$800), cold air intake ($300–$600), or headers ($1,000–$1,500). The Borla S-Type offers the best "seat of the pants" improvement for the money, especially when combined with other mods. It is also a reversible modification—you can reinstall the stock system if you ever sell the vehicle or need to pass strict emissions testing.

Alternative Exhaust Options for the 200 Series

The Borla S-Type is the most popular, but not the only option. Here’s how it stacks up against competitors:

  • Borla Touring: Quieter, similar performance, slightly lower cost (~$1,600). Best for those who want gains without the loud exhaust.
  • Borla Atak: Loudest in the lineup, aggressive, with drone potential. Ideal for off-road-only or enthusiasts who love noise.
  • Magnafab (Magnaflow clone): Budget option (~$900) with less refined sound and potentially lower build quality.
  • MBRP: Aluminum construction, lower cost, but less durable in rust-prone areas.
  • Custom exhaust shop: You can pay a shop to fabricate a mandrel-bent 3-inch system with your choice of muffler for $800–$1,200. However, quality and resale value vary.

The Borla S-Type remains the gold standard for a reason: proven dyno results, excellent fitment, and Borla's strong reputation in the aftermarket.

Tuning and Supporting Mods

To maximize the 30-horsepower gain, consider adding a performance tune. The 200 Series ECU can be reflashed by companies like OV Tuning or DAP. A tune adjusts air-fuel ratio, ignition timing, and throttle mapping to take full advantage of the reduced exhaust backpressure. Expect an additional 10–15 horsepower on top of the exhaust gains.

Other supporting modifications include a high-flow cold air intake (such as aFe, S&B, or K&N) and, for those towing heavy loads, a transmission cooler upgrade. The exhaust alone does not require any other changes, but the engine will run more efficiently with improved intake and airflow.

Long-Term Reliability and Maintenance

The Borla S-Type is built from T-304L stainless steel, which resists corrosion better than the OEM aluminized steel. In areas with snow and road salt, the exhaust will still eventually develop surface rust, but it should last 10+ years. The limited lifetime warranty covers manufacturing defects, but not damage from impacts or improper installation.

Maintenance is minimal: check the clamp bolts annually (especially on off-road vehicles, where vibration can loosen them). The internal packing of the straight-through muffler may gradually degrade after 50,000–60,000 miles, causing a slight increase in exhaust volume. Borla recommends replacing the packing (or the entire muffler section) if it becomes too loud.

Conclusion: Should You Upgrade?

The Borla S-Type exhaust system is a proven, high-quality modification for the Land Cruiser 200 Series. It delivers genuine performance gains—up to 30 horsepower—along with a more thrilling exhaust note and modest weight savings. At $1,800, it is not an impulse buy, but for enthusiasts who value both capability and driving enjoyment, it is one of the best investments you can make. Combined with a supporting tune or intake, the 200 Series can transform from a capable overlander into a genuinely powerful SUV.

Whether you source your Borla S-Type through Fleet or directly from Borla, this upgrade will enhance every mile you drive—from daily commutes to weekend off-road adventures. Install it yourself to save money, or have a professional handle it for peace of mind. Either way, your Land Cruiser will thank you with a smile-inducing exhaust note and newfound grunt.