DINAN D660-0090 Axle Back Freeflow Stainless Exhaust System Instruction Manual

Installation Instructions
D660-0090 & D660-0090-BLK
F95 X5M
AXLE BACK EXHAUST SYSTEM
Document Revision: A

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 maximum benefits for a more aggressive sounding system, 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 they 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

Box Contents

D663-0643
OR
D663-0644|  Exhaust Tips, Polished
OR
Exhaust Tips, Black| 4
/
4

Kit Contents

REMOVAL OF STOCK SYSTEM

STEP 1:
Loosen bolts (red circle) on both left and right tension strut bars
Remove left and right tension strut bars
The installer may need to loosen or remove the undertray to access strut bar

STEP 2:
The following steps include the removal of the rear silencer (2)
The front silencer (1) will remain on the vehicle
If both the Dinan Axle back (D660-0090) and Dinan Mid Pipe (D660-0091) are to be installed at the same time, the entire system can be removed at once from the front of the vehicle.

STEP 3:
Locate the separation point. This is in the location as shown in Step 2
This point shall be marked by a punch mark in the pipe (red circles)
Protect the rear silencer from falling

TEP 4:
Cut through exhaust pipes at the marked point with a suitable tool
Ensure the cuts are perpendicular to the pipes

STEP 5:
Unlock connectors on both the passenger and driver sides of the exhaust
Disconnect the connectors from the exhaust motors

STEP 6:
Use a jack to secure the rear silencer from falling
Loosen and remove the nuts (4x) at the rubber hanger mount locations as shown
Remove the nuts (4x) and carefully lower the rear silencer section

STEP 7:
Loosen and remove the screws holding on the actuator motor
Remove the spring (1), actuator heat shield (2), and actuator motor (3) from both sides of silencer
These parts will be reused

STEP 8:
Remove the 4 rubber hanger mounts from the stock silencer
It is recommended that each one is immediately transferred to the Dinan exhaust system to ensure proper location and orientation

VALVE-ACTUATOR INSTALLATION

Following the diagrams below, attach the actuators, brackets, and springs to the Dinan exhaust valves using the provided hardware.

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DINAN EXHAUST INSTALLATION

STEP 1:
As noted in the final removal step:
Slide all rubber hangers onto the Dinan Exhaust system in the proper orientation.
There is 4 total:

1. or each inlet tube
2. for the axle back muffler section

STEP 2:
Slide the double-wide clamps onto the stock midsection pipes.

STEP 3:
Slide the left and right inlet tubes into the double-wide clamps. Do not tighten in this step.
The image shows the passenger side, repeat for the driver side. Properly seat hangers and secure the vehicle for both pipes.

STEP 4:
Once hanger plates are tightened to the vehicle, adjust the pipe so the rubber hanger is angled towards the front of the vehicle as shown. Repeat for both sides.
Only snug tight the clamps, as an adjustment in the pipes may be needed to properly align the muffler assembly section.

STEP 5:
Place single wide clamps onto the muffler assembly front pipes, on 2 sides.
While holding muffler assembly in place, slide pipes onto the previously installed inlet pipes.
Do not tighten in this step.

STEP 6:
Tubes shall be seated.
Secure hangers to vehicle.
Do not tighten clamps as the adjustment is needed.
Plug-in wiring harness to motor, both sides.

TEP 7:
Place remaining clamps on the 4 tips.
Slide the tips onto the outlet pipes and snug fit but allow for proper alignment.
It is recommended to offset tips approx. 1 inch as shown.

STEP 8:
Ensure the DINAN logo is pointing up and tips are parallel to each other.
** Understand that system may not be seating perfectly at this time. This is where the adjustment will come into play for the final fitment.
Tighten clamps of tips once desired positioning of tips is achieved.

STEP 9:
Add the brace spacer and re-install the braces.
Use the new bolt supplied in the kit.

STEP 10:
Tighten braces and make sure the under panel is secured properly to the vehicle.

STEP 11:
As we are about to adjust the system for proper alignment, there shall be a gap between the pipes and braces, approximately as shown.

STEP 12:
Notice how the tips sit and are positioned in the vehicle. If 1 side is higher than the other, rotation of the inlet tube will help level out the tips.
Have 1 person push the exhaust system towards the front of the car and also upward. This may press the tips into the bumper slightly. Tighten all 4 clamps and let the system rest.
ALL HANGERS SHALL BE ANGLED TOWARDS THE FRONT OF THE AS SHOWN.

FINAL STEP AND CHECK:

1. ENSURE PROPER POSITION OF EXHAUST TIPS
2. ENSURE ALL PIPES HAVE CLEARANCE
3. ENSURE MOTORS ARE PLUGGED INTO THE WIRE HARNESS
4. ADJUSTMENT MAY BE NEEDED ON TIPS AND SYSTEMS IF DESIRED PLACEMENT IS NOT TO YOUR LIKING.

INITIAL DRIVING
The material inside the muffler may smell and/or put out some white smoke during your initial drive.
This is normal and will not occur again once the muffler gets fully hot and the system gets settled in.
Enjoy the additional rowdiness.

ENJOY
Dinan Engineering
4800 US Hwy 280 West
Opelika, AL 36801
Phone: 800.341.5480
INS760-0063 REV. A

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