Why Upgrade to Borla Headers on Your Jeep Wrangler?

Installing Borla headers on your Wrangler is one of the most effective bolt-on upgrades for unlocking horsepower, torque, and a deeper exhaust note. Borla’s high-quality 304 stainless steel construction and mandrel-bent tubing reduce exhaust restriction, allowing the engine to breathe more freely. The result is noticeable throttle response gains, improved mid-range power, and a signature sound that turns heads on the trail or highway. This guide covers the complete installation process for popular Wrangler models equipped with the 3.6L Pentastar V6 or the 2.0L turbo four-cylinder, though the general steps apply to other engines as well.

Tools and Parts You’ll Need

Before diving into the work, gather the correct tools and replacement parts. Using the right equipment saves time and prevents damage to your new headers or engine components.

Required Tools

  • Socket set – 1/2-inch drive preferred, with metric sockets (10mm, 13mm, 15mm, 18mm)
  • Combination wrenches – same sizes as sockets, plus a 21mm for O2 sensors
  • Torque wrench – 3/8-inch and 1/2-inch drive, capable of 15–45 ft-lbs
  • Breaker bar – handles stubborn rusted bolts
  • Jack and jack stands – rated for your Wrangler’s weight
  • Penetrating oil – like PB Blaster or Liquid Wrench
  • Safety glasses and mechanic’s gloves
  • O2 sensor socket – 7/8-inch (22mm) offset or crowfoot
  • Gasket scraper or plastic razor blade
  • Anti-seize compound – for bolt threads and O2 sensor threads

Borla Header Kit Contents

  • Borla headers (left and right, or single unit for turbo models)
  • New exhaust gaskets
  • Header bolts and studs (if not reusing OEM)
  • Hardware for O2 sensor extensions if needed

Borla headers are available as part of their official product lineup; always verify fitment by entering your Wrangler’s year, model, and engine option.

Preparation and Safety

Proper preparation prevents mistakes and injuries. Work in a well-ventilated garage or driveway on a level surface. Follow these steps to set up your workspace:

  1. Disconnect the negative battery terminal to avoid accidental electrical shorts or triggering the check engine light during the swap.
  2. Engage the parking brake and chock the rear wheels.
  3. Raise the front of the Wrangler with a floor jack and secure it on jack stands placed under the frame rails. Never rely on the hydraulic jack alone.
  4. Remove the front skid plate if your Wrangler has one (common on Rubicon models). You may need a 15mm socket and a helper to hold the plate while removing bolts.
  5. Spray all header bolts, exhaust manifold flange nuts, and O2 sensor connections with penetrating oil. Allow it to soak for at least 15 minutes.

Removing the Factory Exhaust Manifolds

The factory exhaust manifolds on Wranglers are notorious for cracking and warping over time, especially on earlier 3.6L engines. Removing them requires patience, especially for bolts that have seen heat cycles and road salt.

Disconnect O2 Sensors

Locate the upstream O2 sensors in the exhaust manifolds. Unplug the electrical connectors and carefully unscrew the sensors using your O2 sensor socket. Apply anti-seize to the threads of the new sensors before reinstallation later. If the sensor is stuck, use a specialty O2 sensor removal tool to avoid stripping.

Remove Heat Shields (if equipped)

Many Wrangler models have stamped metal heat shields over the exhaust manifolds. Use a 10mm or 13mm socket to remove the bolts and set the shields aside. You may discard them when installing new headers since Borla headers often have integrated heat management, but check your kit instructions first.

Unbolt the Old Manifolds

  1. Working from the top, reach between the intake manifold and cylinder head to access the exhaust manifold bolts. Use a combination of sockets and wrenches to break them loose.
  2. Lower engine mounts may need to be loosened to tilt the engine forward slightly for clearance. This is especially helpful on the 3.6L where the driver-side manifold is tight against the frame.
  3. Remove the bolts in a crisscross pattern and lift the manifold off the cylinder head. If it does not come free easily, double-check that all bolts are removed and gently tap with a rubber mallet.
  4. For the passenger side, you may need to remove the alternator or loosen it for access. Mark the alternator bolts for easy reinstallation.
  5. Clean the cylinder head mating surfaces thoroughly using a gasket scraper. Remove all old gasket material and carbon deposits. Avoid scratching the aluminum head surface.

Torque specifications for the factory exhaust manifold bolts can be found in your vehicle’s service manual or online resources like Wrangler Forum. Typical spec is around 18 ft-lbs for the 3.6L Pentastar manifold bolts, but new Borla header bolts may have different requirements – always follow the Borla instructions.

Installing Borla Headers

With the old manifolds removed and the head surfaces clean, it’s time to mount the Borla headers. Borla headers are precision-engineered to fit without modification, but the process still demands attention to detail.

Gasket and Header Placement

  1. Apply a thin coat of copper anti-seize or spray copper gasket sealant to both sides of the new exhaust gaskets. Borla includes gaskets that are typically multi-layer steel; ensure they are oriented correctly.
  2. Hold the header in position against the cylinder head. Start the bolts by hand to avoid cross-threading. Borla provides high-strength header bolts – use a drop of anti-seize on the threads.
  3. Tighten bolts in the recommended torque sequence (usually center-outward) to 18–22 ft-lbs using a torque wrench. Do not overtighten; header flanges are thick but pulling too hard can warp the flange.
  4. For V6 models, repeat the same process on the other bank.

Connecting Exhaust Pipes and O2 Sensors

  • Borla headers will have a collector flange that mates to your Jeep’s mid-pipe or catalytic converter. Use the supplied hardware and a new gasket (many Wranglers use a donut gasket at this joint).
  • Hand tighten the collector bolts, then torque to around 25–30 ft-lbs. Do not fully tighten until all other connections are aligned to prevent binding.
  • Reinstall O2 sensors into the header bungs. Borla often provides extended harnesses or relocates the sensor bung further downstream to prevent CELs. If included, route the harness away from heat and sharp edges.
  • Apply anti-seize to the O2 sensor threads before installing each sensor. Torque to about 30 ft-lbs (do not overtighten).

Reattach Heat Shields and Other Components

If your Borla headers require the factory heat shields reattached, do so now using the original bolts. Many aftermarket headers are designed to be installed without shields, but confirm with Borla’s instructions. Reinstall any components you removed: alternator, engine mount bolts, skid plate, and other hardware.

Final Assembly and Testing

Once the headers are in place and all bolts are torqued to specification, perform a thorough inspection before starting the engine.

Check for Clearance and Leaks

  • Rotate the steering wheel lock-to-lock (engine off) to ensure the header doesn’t contact the steering shaft or linkage.
  • Check all electrical connectors, vacuum lines, and wiring harnesses are securely routed away from the hot exhaust.
  • Reconnect the negative battery terminal.

Start the Engine and Listen

  1. Start the engine and let it idle for a minute. You will hear an initial metallic smell as the headers heat up – this is normal for new stainless steel.
  2. Check for exhaust leaks at the header-to-head connection, collector flanges, and O2 sensor bungs. A small leak produces a ticking sound that increases with engine speed. If you hear ticking, tighten the affected bolts slightly or use an exhaust sealant on the gaskets.
  3. Let the engine reach operating temperature and re-torque the header bolts once they have cooled. Stainless steel expands with heat; a second torque pass ensures a lasting seal.

Post-Installation Tips

  • ECU Adaptation – After installing headers, the engine computer may take a few drive cycles to adjust fuel trims. A cold air intake and cat-back exhaust combined with headers will maximize gains, but consider a tune to fully utilize the improved flow.
  • Sound Check – Borla headers produce a deeper tone. If your Wrangler still has a factory muffler, the sound will be moderate; pairing with a Borla cat-back system creates a more aggressive exhaust note.
  • Warranty – Borla headers carry a limited lifetime warranty against defects in materials and workmanship. Retain your purchase receipt and register the product online.
  • Future Maintenance – Stainless steel headers resist corrosion well, but check the bolts annually for tightness. Consider upgrading to locking header bolts to prevent loosening due to thermal cycling.

For further technical information and owner experiences, visit JL Wrangler Forums or consult Borla’s support page.

Conclusion

Upgrading your Wrangler with Borla headers is a rewarding project that delivers real performance and acoustic improvements. The installation requires patience and attention to torque specifications, but with the right tools and this step-by-step guide, you can complete the job in a weekend. Your Jeep will respond with stronger throttle response, a more satisfying exhaust note, and the confidence that you’ve installed one of the best header kits on the market. Enjoy your upgraded ride!