DINAN D660-0089-BLK Exhaust System Instruction Manual

D660-0089-BLK Exhaust System
Instruction Manual

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 TechnicalSupport Staff at 800-341-5480.

Again, thank you for choosing Dinan. Enjoy.

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
2018-2021 MINI JCW Countryman ALL4

Document Revision: B
Release Date: February 23, 2021

Parts List

OR
2| D663-0601| 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 the stock system. The stock hangers will be re-used.

Installation of Exhaust Valve Wiring:

1. Unplug the stock exhaust valve motor.

2. Attach the Dinan Extension Harness to the stock exhaust valve plug.
   

3. Loosen the heat shield bolts and run the wiring underneath the heat shield and across to the other side of the car.
   

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.

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.
   

3. Using supplied hardware, install the motor and spring as shown in Figure 6.
   

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.

4. Do not tighten as adjustment of pipe will be needed.

5. Slide the double bolt clamp onto the inlet tube as shown.
   

Axle Back

1. Install stock hangers onto the Dinan muffler system, Figure 8.

2. Lift the muffler assembly up into place.

3. Install the 2 nuts for the hanger mounts and tighten them, Figure 9.
   

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. 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 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 the space between the bumper is to your liking, tighten the coupler clamps.
4. Ensure the motor is plugged into the harness plug.

Clamp Torque Settings
All clamps shall be torqued to 45 ft-lbs.

Installation is complete. ENJOY

Documents / Resources

| DINAN D660-0089-BLK Exhaust System [pdf] Instruction Manual
D660-0089-BLK, D660-0089, Exhaust System
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