DINAN D660-0096 Valved Cat-Back Exhaust System Instruction Manual

DINAN D660-0096 Valved Cat-Back Exhaust System

Product Information

The Dinan Performance Exhaust System is a high-quality aftermarket exhaust system designed to enhance the performance,sound, and aesthetics of your vehicle. Developed by the Dinan Engineering Team, this exhaust system offers maximum benefits, including a more aggressive sound, increased performance, durability, and an aesthetically pleasing design that you can enjoy for years to come. Ease of installation and maintenance has been a priority during the design process.

Product Details:

• Manufacturer: Dinan Engineering
• Model: Performance Exhaust System
• Part Number: INS660-0096(-BLK)
• Release Date: 4/12/2023

Parts List:

Hardware Kit Contents:

Product Usage Instructions

Prior to installation, please read and familiarize yourself with the following instructions:

1. If you do not possess the required skills or tools, it is recommended to arrange for a qualified repair facility to perform the installation.
2. If you encounter any difficulties during the installation or find the instructions unclear, please contact Dinan’s Technical Support Staff at 800-341-5480 for assistance.

Removal of Stock System:

Step 1: Unplug the connector from the valve motor located on the driver side of the stock exhaust.

Step 2: Remove the entire stock system, including the brace as shown in the instructions.

Step 3:

• Loosen the clamp at the front of the vehicle post catalytic converter (red).
• Loosen and remove the nut from the hanger mount (green).

Step 4:

• Locate the 3 rubber hangers.
• Loosen and remove the screws holding on the actuator motor.
• Remove the spring (1), actuator heat shield (2), and actuator motor (3). The motor (3) will be re-used.

Step 5: Remove the 3 rubber hanger mounts from the stock exhaust.

Dinan Engineering
4800 US Hwy 280 West
Opelika, AL 36801
Phone: 800.341.5480

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 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.

Installation Instructions

D660-0096 & D660-0096-BLK
A90 SUPRA – 6 CYL
EXHAUST SYSTEM

Document Revision: A
Release Date: 4/12/2023

PARTS LIST

Box Contents

D663-0645 OR

D663-0646

| POLISHED EXHAUST TIPS

OR

BLACK EXHAUST TIPS

| 2

2

Hardware Kit Contents

REMOVAL OF STOCK SYSTEM

STEP 1:
Unplug the connector from the valve motor located on driver side of the stock exhaust.

STEP 2:
The entire stock system will be removed.
Remove brace as shown.

STEP 3:
Loosen clamp at the front of the vehicle post catalytic converter (red).
Loosen and remove nut from hanger mount (green).

Locate the 3 rubber hangers.

• 2 are located near the rear of the vehicle on both passenger and driver side as shown
• 1 is located near rear axle

Remove the 3 rubber hanger nuts from the vehicle.
This will drop the exhaust from the vehicle. A stand or 2nd person is recommended to help lower the system from the vehicle.

STEP 4:
Loosen and remove the screws holding on the actuator motor.
Remove the spring (1), actuator heat shield (2) and actuator motor (3).
The motor (3) will be re-used.

STEP 5:
Remove the 3 rubber hanger mounts from the stock exhaust.
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.

IT IS NECESSARY THAT THE SPRING IS COMPRESSED AGAINST THE VALVE AND THE MOTOR DURING ASSEMBLY. IF THIS IS NOT THE CASE, PLEASE STRETCH THE SPRING OUT SLIGHTLY. FAILURE TO DO SO MAY CAUSE UNNECESSARY VIBRATION NOISES.

DINAN EXHAUST INSTALLATION

STEP 1:
STEPS 1-4 include installation of the extension wire harness:
Remove the screws from the panel on the side of the stock motor connector.

STEP 2:
The stock harness is attached to the heat shield as shown.
Pull the harness through the isolator mounts to extend a few more inches.
Rotate the mount 180 degrees such that the connector will feed back under the panel.
Connect the extension harness as shown.

STEP 3:
The proper routing at this position shall look like this.

STEP 4:
Route the extension harness behind the heatshield.
The harness shall be pulled through the opening of the hanger mount that is next to the valve and motor.
Pull enough out to connect to the motor once the exhaust is installed.
Re-install all screws that were removed from the panel at this time.

STEP 5:
As noted in the final removal step:
Slide all rubber hangers onto the Dinan Exhaust system in the proper orientation.

There are 3 total:

1. for the middle inlet tube
2. for the axle back muffler section
   Image is for reference only

STEP 6:
Slide 1 of the clamps onto the front inlet pipe.
Slide the inlet pipe onto the stock pipe. Position of this pipe is dictated by the hanger position.
Install and tighten the nut at the hanger (green). This shall position the inlet tube.
Tighten the clamp.

STEP 7:
Slide a clamp onto the middle inlet pipe and slide the middle inlet pipe over the already positioned front inlet pipe.
Properly seat hanger and tighten the nuts to the vehicle (green).
Only snug tight the clamp, as adjustment in the pipes may be needed to properly align the muffler assembly section.
RE-INTALL BRACE AND TIGHTEN AT THIS STEP

STEP 8:
Slide 1 clamp over the rear muffler section inlet pipe.
With the help of a friend, take the muffler section and slide the inlet pipe over the already positioned middle inlet pipe.
Overlap shall be approx. 2”
Do not tighten clamp at this time.

STEP 9:
Once Step 8 is complete, properly seat hangers and tighten the nuts to the vehicle in both locations shown.
Ensure the nuts are tightened properly.
Again, do not fully tighten any clamps as adjustment may be needed. This will be done in later steps.

STEP 10:
Slide the remaining 2 clamps onto the exhaust tips as shown.

STEP 11:
Slide each clamp onto the outlet pipes of the exhaust with the tightening bolt in the orientation as shown.
Snug fit for positioning.

STEP 12:
Ensure DINAN logo is pointing up and tips are parallel to each other. The CENTER shall be between the ‘N’ and ‘A’ in DINAN. This shall be pointing straight up.
The tips may not be exactly evenly spaced from the bumper. We will fix this later.
Recommended tip position is shown. It is the desire of the customer on how far in or out they choose, as long as there is enough clamping surface.
Tighten the tip clamps once desired positioning of tips is achieved.

STEP 13:
Once the tips are tightened, final adjustment is needed.
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.
Proceed to the next step.
ALL HANGERS SHALL BE STRAIGHT DOWN OR ANGLED TOWARDS THE FRONT OF THE AS SHOWN.

STEP 14:
Tighten the 2 clamps connecting the muffler section to the middle inlet pipe and the middle inlet pipe to the front inlet pipe. Let the system rest.
Examine the position of the tips and ensure that they are equally positioned from left to right. Examine to ensure proper clearance throughout the system.
Adjustment may be needed. Rotation of the inlet pipes may be necessary.
Once desired position is reached, ensure all clamps on both pipes and tips are fully tightened. Don’t be shy.

STEP 15:
Connect the extension harness to the motor as shown.
Feed any slack back into the heat shield opening.

FINAL STEP AND CHECK

1. ENSURE PROPER POSITION OF EXHAUST TIPS
2. ENSURE ALL PIPES HAVE CLEARANCE
3. ENSURE MOTOR IS PLUGGED INTO WIRE HARNESSES
4. REVIEW FINAL POSITION AND ENSURE ALL CLAMPS ARE TIGHT
5. ENJOY

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