Instruction Manual for DINAN models including: D660-0089, D660-0089-BLK, Valved Axle Back Exhaust, D660-0089 Valved Axle Back Exhaust
Dinan D660-0089-BLK Dinan Valved Axle-Back Exhaust - 2016-2023 BMW X1/X2 xDrive28i & 2016-2023 MINI C'Man JCW
D660-0089(-BLK) Installation Instructions Installation Instructions D660-0089 and D660-0089-BLK EXHAUST SYSTEM Vehicle Application List: 2016-2021 X1 xDrive28i 2018-2021 X2 XDrive28i 2016-2021 MINI JCW Clubman ALL4 Thank you for being selective enough to choose a Dinan Performance Exhaust System. The Dinan Engineering Team has spent many hours developing this product to assure that you will receive increased performance, durability and an aesthetic design that you as a customer will be able to enjoy for many years. Ease of installation and maintenance is important to us and has been highly considered throughout the design process. 2018-2021 MINI JCW Countryman ALL4 Document Revision: B Release Date: February 23, 2021 Prior to performing the installation, familiarize yourself with these instructions as it should help you with the process. If you feel that you do not have the required skills or tools, please arrange for a qualified repair facility to perform the installation. Contents Parts List ....................................... 2 Removal: Stock System ...................... 3 Installation of Exhaust Valve Wiring: ...... 4 Assembly: Valve Brackets/Motor ........... 5 If you have any difficulties during the installation, or if these instructions are not clear to you, please call Dinan's Technical Support Staff at (800) 341-5480. Again, thank you for choosing Dinan. Enjoy. Installation:.................................... 7 Inlet Tube ..................................... 7 Axle Back ...................................... 8 Exhaust Tips.................................. 10 Exhaust Adjustment......................... 11 Clamp Torque Settings ..................... 11 Page 1 of 11 Parts List D660-0089(-BLK) Installation Instructions Quantity 1 1 2 1 1 1 3 3 2 1 9 3 5 1 6 1 2 2 Part# Description D663-0360 D662-0653 D662-0652 Muffler Assembly; F60 Inlet Tube; F60 AWD Outlet Extension D663-0368 D662-0433 D662-0665 D671-0189 D671-0193 D671-0377 D671-0378 M6 Flat M6 Wave D662-9228 D662-9241 D502121 D662-0431 Hardware Kit Exhaust Valve Mount D76 Limiter M6 Locknut M6x20 Socket Head Bolts M6x12 Socket Head Bolts M6x16 Socket Head Bolts Washer Washer Single Bolt Clamp, 69.9mm Double Bolt Clamp, 69.9mm 5" Tie Straps Extension Harness D663-0600 OR D663-0601 4" Exhaust Tip, Polished 4" Exhaust Tip, BLK Page 2 of 11 D660-0084(-BLK) Installation Instructions Removal: Stock System 1) Cut the exhaust pipe 2 ¾", measured from the rearmost stock cut dimple. 2) Ensure the exhaust system is supported and unbolt the hanger assembly from the car. 3) Remove the cut stock system from the car. 4) Remove rubber grommets from stock system. The stock hangers will be re-used. Figure 1: Cut Point After cutting the exhaust, remove these 2 hangers Figure 2: Hanger Location Page 3 of 21 D660-0089(-BLK) Installation Instructions Installation of Exhaust Valve Wiring: 1) Unplug the stock exhaust valve motor. 2) Attach the Dinan Extension Harness to the stock exhaust valve plug. Figure 3: Attaching the Dinan Harness 3) Loosen the heat shield bolts and run the wiring underneath the heat shield and across to the other side of the car. Figure 4: Removing Exhaust Heat Shield 4) Once the wiring is run across, secure the heat shield back in place with the wiring behind it. Be sure not to pinch the wire with any of the heat shield screws. Page 4 of 11 D660-0089(-BLK) Installation Instructions Assembly: Valve Brackets/Motor 1) Assemble the exhaust valve mount (blue) and D76 limiter (orange) to the valve as shown in Figure 5. 2) Ensure all bolts are tight. Figure 5: Assembly- Valve Bracket Page 5 of 11 D660-0089(-BLK) Installation Instructions 3) Using supplied hardware, install motor and spring as shown in Figure 6. Figure 6: Assembly: Valve Motor Page 6 of 11 D660-0089(-BLK) Installation Instructions Installation: Inlet Tube Refer to Figure 7 below for installation. 1) Slide the single bolt clamp over the inlet tube end with the slots. 2) Ensure the bolt is facing down as shown in Figure 7. 3) Slide the inlet tube over the stock exhaust at the cut point. a. Snug fit clamp. b. Do not tighten as adjustment of pipe will be needed. 4) Slide the double bolt clamp onto the inlet tube as shown. 69.9 mm clamp, double bolt 69.9 mm clamp, single bolt Figure 7: Inlet Tube Page 7 of 11 D660-0089(-BLK) Installation Instructions Axle Back 1) Install stock hangers onto Dinan muffler system, Figure 8. 2) Lift muffler assembly up in to place. 3) Install the 2 nuts for the hanger mounts and tighten, Figure 9. Figure 8: Hanger Installation Figure 9: Exhaust Hanger Installation Page 8 of 11 D660-0089(-BLK) Installation Instructions 4) Slide the wide coupler clamp over the muffler pipe, splitting the difference between the cut. 5) From the rear of the vehicle: a. Push the exhaust system from the rear of the vehicle up and towards the front of the car and lightly tighten the coupler clamp. b. Final adjustment and tightening of clamps will be conducted after installation of tips. Lightly tighten clamp Figure 10: Setting Muffler Page 9 of 11 D660-0089(-BLK) Installation Instructions Exhaust Tips 1) Install the tip extensions to the end of the exhaust. Push the tip extension onto the exhaust and loosely tighten. **This extension is model specific and may not be needed for your vehicle model. If tips can be positioned below without extension, do not use extension** 2) Slide the 69.9mm clamp onto the tip flange. a. Bolt shall be aligned with the DINAN logo (top side). b. The bolts should face towards the outside of the car. Figure 11 shows the passenger's side tip. The driver's side tip should have the bolt end facing the opposite direction. 3) The tips should be clocked where the middle of the first N is centered. a. Line up the tips where the bumper is aligned to the Figure 11: Tip Clamp Location tip edge. b. Once the tips are aligned, tighten the tip clamps until tips are secure and do not move. Figure 12: Tip Extensions and Tip Position on Vehicle Page 10 of 11 D660-0089(-BLK) Installation Instructions Exhaust Adjustment Small adjustments may be needed on the Inlet Tube in order to center the tips appropriately. The following is recommended. 1) Push the tips up and towards the front of the car. 2) Snug fit all clamps and check tip alignment. 3) Once the tips are even on both sides and spaced between the bumper to your liking, tighten the coupler clamps. 4) Ensure motor is plugged into harness plug. Clamp Torque Settings All clamps shall be torqued to 45 ft-lbs. Figure 13: Tip Fitment Installation is complete. ENJOY Page 11 of 11Microsoft Word 2019