DINAN D660-0083 Valved Axle Back Exhaust Installation Guide

D660-0083(-BLK)
Installation Instructions D660-0083(-BLK) EXHAUST
Vehicle Application List:
2016-20 F60 MINI COOPER S
COUNTRYMAN FWD
2016-20 F54 MINI COOPER S
CLUBMAN FWD

D660-0083 Valved Axle Back Exhaust

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

Removal of Stock Exhaust System:

1. Cut 2-3/4” from the brace, towards the back of the car.
2. Support the exhaust and remove the hangers from the car.
3. Remove the stock system from the car.

Installation of Dinan System:

1. Slide the 63.5mm clamp onto the inlet tube on the ends with the slots.
2. Slide the inlet tube onto the exhaust at the cut point.
3. Make sure the clamp is facing the driver’s side with the bolts facing down.
4. Slide the coupler clamp onto the inlet tube.

Exhaust Valve Assembly:

1. ) Assemble the exhaust valve bracket and actuator as shown in the figures below.

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Installation of Dinan Muffler:

1. Remove the rubber hangers from the stock exhaust.
2. Slide the hangers onto the Dinan Muffler.
3. Lift muffler assembly up in to place.
4. Install the 2 nuts for the hanger mounts.
5. Slide the coupler clamp on, push up on the exhaust and toward the front of the car, and lightly tighten the coupler clamp.

Installation of Exhaust Tips:

1. Install the 69.9mm clamp on tips with bolts clocked towards logo.
   • The bolts should face towards the outside of the car.
   • The tip pictured is 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.
   • Line up the tips where the bumper is aligned to the tip edge.
   • Once the tips are aligned, tighten the tip clamps without damaging the pipe.

3. To adjust the fitment, twist the inlet tube to adjust the tip fitment.

4. Push the tips towards the front of the car and tighten the coupler clamps.
   Torque all clamps to specifications listed below:
   • Exhaust Tip Clamps: 45 ft-lbs
   • Torca Coupler (2-Bolt) Clamp: 45 ft-lbs
   • 1-Bolt Adapter Clamp: 45 ft-lbs

For the F60 Countryman MINI Chassis go to page 11
For the F54 Clubman MINI Chassis go to page 20

Installation of Wiring for Exhaust Valve for F60

1. On the driver’s side wheel well, remove this screw and move the wheel well shield out of the way.
   a. Pulling back the shield and locate the grommet.
   b. Remove this grommet.
   c. Feed the connector plugs into the grommet hole and install the grommet into the hole.

2. Open the rear hatch and look to the left.
   a. Remove this small panel from the trunk wall.
   b. Raise the floor panel.

3. Remove all the marked pins in the pictures below from the trunk trim and carefully remove the trim.

4. Carefully move the driver’s side paneling back (if vehicle is equipped with a cargo net, the attachment may need to be removed as well).
   a. Locate the wires you fed through in step 2 in the pocket below the panel.
   b. Pull the wires up.

5. Locate the control box in your provided kit and attach the red and white wires you’ve just pulled through.
   a. Attach the control box to the driver’s side trunk wall with the supplied Velcro or Zip Tie.

6. On the second set of wires, there is a black wire and a red wire with a small fuse attached.
   a. Plug the red wire into the second red plug on the control box.
   b. 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.

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

8. Grab the red power wire you pulled through and the dome light power cable.
   a. Use the provided Scotchlok adaptor to splice the red power wire to the red and yellow cable attached to the dome light (some vehicles may use a different color code – please verify the presence of 12V power before making the connection).
   b. Place the 12V vehicle power wire inside appropriate channel.
   c. Insert the red Dinan Power Wire into the other side of the Scotchlok.
   d. Crimp the metal tab onto both wires until it is flush with the top of the Scotchlok.
   e. Close hinged top cover until latched.f. After splicing, reinstall the dome light.

9. 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 a good contact on the lug and secure the wire.

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

11. Continue installation process at Step 1 under “Finishing Installation” on the bottom of Page 24.

Installation of Wiring for Exhaust Valve for F54

1. On the driver’s side wheel well, remove this screw and move the wheel well shield out of the way.
   a. Pulling back the shield and locate the grommet.
   b. Remove this grommet.
   c. Feed the connector plugs into the grommet hole and install the grommet into the hole.

2. Open the trunk and remove the driver’s side paneling on the trunk wall (if vehicle is equipped with a cargo net, the attachment may need to be removed as well).

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

4. Attach the control box to the wiring harness and secure it to the frame rail with the provided Velcro strips.

5. Attach the ground wire to the wheel well arch lug.

6. Grab the red power wire from the provided wiring harness and the red/yellow dome light power cable (some vehicles may use a different color code – please verify the presence of 12V power before making the connection).
   a. Use the provided Scotchlok adaptor to splice the red power wire to the red and yellow cable attached to the dome light.
   b. Place the 12V vehicle power wire inside appropriate channel.
   c. Insert the red Dinan Power Wire into the other side of the Scotchlok.
   d. Crimp the metal tab onto both wires until it is flush with the top of the Scotchlok.
   e. Close hinged top cover until latched.

7. Using the provided zip-ties, clean up the excess wiring and secure it as it is pictured below. Reinstall the trunk panel that was removed in Step 2.

Finishing Installation

1. Underneath the car, support the exhaust and remove the nut for the hanger mount on the driver side, marked below.

2. Lightly sand and clean the hanger mount and attach the short ground cable to the hanger mount.
   a. Torque the hanger nut back in place.

3. Plug the exhaust valve motor in, leaving at least 1 inch of slack in the cable.
   a. Make sure the cable is not contacting anything sharp or hot.
   b. To adjust cable length, pull or push cabling from the grommet.

4. Power the car on and test the key fob remote to ensure both the remote and the valve work properly.

5. Reinstall the screw in the wheel well from Step 1.

6. Installation is done.

Document Revision: E
Release Date: February 17, 2023

Documents / Resources

| DINAN D660-0083 Valved Axle Back Exhaust [pdf] Installation Guide
D660-0083, D660-0083 Valved Axle Back Exhaust, Valved Axle Back Exhaust, Axle Back Exhaust, Exhaust
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