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I am going to replace the exhaust system and intake with a Blackwing and (probably) Borla exhaust. Aside from all the advertising hype what could I reasonably expect in a HP improvement, and will my fuel consumption suffer?
I assume youre talking about a cat back eh? You wont notice very much difference if thats the case. Save your money, buy headers, X pipe along with your cat back and CAI.... then youll notice a real difference. Your gas mileage will probably suffer only because youll tend to rev a little higher because youll like the new exhaust note.
"what could I reasonably expect in a HP improvement"
What does this mean to you?
There will be an improvement and probably a slight increase in mpg's if you drive the same.
When changing filters and exhaust, the gains are typically in the upper rpm's. So, if you want more "power" in the normal driving rpm's then you may be a little disappointed.
You may notice that because it can rev more freely, the improved throttle response may be noticed. Maybe.
I noticed an improvement above 4500 or so after installing Borla straight pipes and a Blackwing. But it wasn't until I removed the cats that I saw a bigger improvement it the engines ability to rev quicker at higher rpm's.
I have a Blackwing with an Icebox, vararam powerduct with relocated MAF and TI exhaust, did the mods this past winter, no noticeable power gain, though the fuel economy went up by about 1.5 mpg in the city.