DINAN D660-0084 Valved Axle-Back Exhaust System Instruction Manual

D660-0084(-BLK) Installation Instructions
Installation Instructions
D660-0084 and
D660-0084-BLK
EXHAUST SYSTEM
Vehicle Application List: 2017-2021 F54 MINI Clubman S ALL4
017-2021 F60 MINI Countryman S ALL4
Document Revision: A
Release Date: February 19, 2021

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.
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.
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.

Parts List

Quantity

| Part#| Description
---|---|---
1| D663-0360| Muffler Assembly; F60
1| D662-0653| Inlet Tube; F60 AWD
1| D663-0366| Hardware Kit
1| D662-0433| Exhaust Valve Mount
1| D662-0665| D76 Limiter
3| D671-0189| M6 Locknut
3| D671-0193| M6x20 Socket Head Bolts
2| D671-0377| M6x12 Socket Head Bolts
1| D671-0378| M6x16 Socket Head Bolts
9| M6 Flat| Washer
3| M6 Wave| Washer
3| D662-9228| Single Bolt Clamp, 69.9mm
1| D662-9241| Double Bolt Clamp, 69.9mm
1| D663-0353| Exhaust Valve Controller Kit
1| ELO-501| Red Scotchlok Con
4| DT441-0022| Velcro Strip
6| D502121| 5″ Tie Strap
1| D661-0031| Exhaust Valve Spring
1| D661-0032| Heat Shield, Valve Motor
1| D661-0033| Exhaust Valve Motor
1| D662-0643| Valve Motor Fob t Controller
1| D662-0644| Exhaust Valve Harness; Main
1| D662-0645| Exhaust Valve Harness; PWR
1| D662-0646| Exhaust Valve Harness; GND
2| D663-0600| 4″ Exhaust Tip, Polished

OR

2| D663-0601| I 4″ Exhaust Tip, BLK

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.

Assembly: Valve Brackets/Motor

1. Assemble the exhaust valve mount (blue) and D76 limiter (orange) to the valve as shown in Figure 3.

2. Ensure all bolts are tight.
   

3. Using supplied hardware, install motor and spring as shown in Figure 4.

Installation:

Inlet Tube
Refer to Figure 5 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 5.

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.

Axle Back

1. Install stock hangers onto the Dinan muffler system, Figure 6.
2. Lift muffler assembly up into place.
3. Install the 2 nuts for the hanger mounts and tighten them, Figure 7.
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.

Exhaust Tips

1.  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 9 shows the passenger’s side tip. The driver’s side tip should have the bolt end facing the opposite direction.

2. 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 tip edge.
   b. Once the tips are aligned, tighten the tip clamps until tips are secure and do not move.

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.
   Clamp Torque Settings All clamps shall be torqued to 45 ft-lbs.
   F60 Countryman MINI Chassis go to Appendix: Wiring Valve for F60
   F54 Clubman MINI Chassis go to Appendix: Wiring Valve for F54

Appendix:

Wiring Valve for F60

1. On the driver’s side wheel well, remove the screw as shown in Figure 13.

2. Pull back the shield, locate and remove the grommet.

3. Feed the connector plugs into the grommet hole and re-install the grommet.

4. In the trunk location, remove the panel on the driver’s side and then raise the floor panel.

5.  Remove all the marked pins in Figure 15 and Figure 16. Remove the trunk trim.

6. Pull back the driver’s side panel, and locate the connector plug wires that were fed through the grommet in step (3). Pull wires up.

7.  Locate the control box and attach the wires you’ve just pulled through. Red-Red. White-White.

8. Attach the control box to the driver’s side trunk wall with the supplied Velcro or Zip Tie as shown in Figure 18.

9. On the second set of wires, there is a black wire and a red wire with a small fuse attached. Plug the red wire into the second red plug on the control box. Run the wire from the control box to the passenger’s side panel, running the wires behind any paneling using zip ties to secure the wires.

10. On the passenger’s side, locate and remove the dome light from its housing. Run the red wire into the dome light hole.
    

11. Attaching to power: Figure 21.a) Locate red and yellow wire attached to the dome light
    b) Lay this wire into the Scotchlok connector as shown. It will feed through.
    c) Insert the red Dinan Power Wire into the other side of the connector.
    d) Crimp the metal tab onto both wires and close the hinge until it is latched

12. Re-install dome light.

13.  On the driver’s side, behind the removed panel from step 3, locate the ground lug.
    a) Attach the longer ground wire with an eyelet on one end and a bullet connector on the other end
    to the lug and plug the wire into the control box.
    b) Make sure you have good contact on the lug and secure the wire.
    

14.  Check all wiring connections, attach zip ties where needed, and reinstall the trunk interior.

15. Continue installation process at Final Installation on page 20.

Wiring Valve for F54

1. On the driver’s side wheel well, remove the screw as shown in Figure 24.

2. Pull back the shield and locate and remove the grommet.

3. Feed the connector plugs into the grommet hole and re-install the grommet.

4. Open the trunk and remove the driver’s side paneling on the trunk wall.

5. Pull the wiring up and through the grommet hole into the cavity below the dome light.

6.  Attach the control box to the driver’s side trunk wall with the supplied Velcro or Zip Tie as shown in Figure 26.

7. Make sure all surfaces are clean and attach the ground wire to the wheel well lug.

8. Attaching to power: Figure 28
   a) Locate red and yellow wire attached to the dome light.
   b) Lay this wire into the Scotchlok connector as shown. It will feed through.
   c) Insert the red Dinan Power Wire into the other side of the connector.
   d) Crimp the metal tab onto both wires and close the hinge until it is latched.

9. Using the provided zip-ties, cable manages excess wiring. Reinstall the trunk panel and dome light.

Final Installation
This section applies to both the F60 and F54 platforms. It is the final electrical installation needed for the system to work properly.

1. Underneath the car, remove the nut for the hanger mount on the driver’s side, marked below.

2. Ensure the hanger mount surface is clean and free of contaminants. This is important as it is a grounding surface. Light sanding may be needed. Attach black ground cable. Tighten nut.

3. Plug the exhaust valve motor in, leaving at least 1 inch of slack in the cable. Adjust cable entering grommet to allow for slack. Ensure the cable is not touching the exhaust system or anything sharp.
   

4. Reinstall the screw in the wheel well from the initial step.

5. Power the car on and test the key fob remote to ensure both the remote and the valve work properly.
   Installation is complete. Thank you for choosing a Dinan Exhaust. Enjoy!

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