Dinan D660-0085 Free Flow Stainless Exhaust Systems Instruction Manual

D660-0085 Free Flow Stainless Exhaust Systems
Instruction ManualD660-0085 / D660-0085-BLK
EXHAUST SYSTEM
Vehicle Application List:
2020-2021 G20 M340i & xDrive
2021 G22 M440i xDrive
Document Revision: C
Release Date: June 3, 2021

D660-0085 Free Flow Stainless Exhaust Systems

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.
D660-0085 / D660-0085-BLK

Parts List

Removal of Stock System

1. Support and cut the stock exhaust at the factory cut point.
   
2. Remove both of the stock tips and unplug the exhaust valve.
   
3. Unbolt the exhaust hangers and remove the stock muffler.
4. Loosen the passenger’s side panel in the muffler cavity and route the wiring as indicated below.
   
5. Remove the rear black panel.
   
6. Route the wiring through the clips in the back bumper, above where the back panel mounts.
   
7. Loosen the driver’s side panel and route the wiring as pictured below. Leave about 8 inches of wiring length on this side.
   
8. Secure the driver’s side panel back in place. You may need to adjust this cable length later.
   
9. The muffler cavity should look like the picture below.
   
10. Following the diagrams below, attach the actuators, brackets, and springs to the Dinan exhaust valves using the hardware provided.
    
11. Install the hangers onto the inlet pipes and install the inlet pipes. Loosely tighten the clamps, but do not fully torque yet.
    
12. Install the Dinan muffler by attaching the hangers and slipping the clamps over the inlet pipes.
    
13. Adjust the wiring length on either side to allow the valve motors to plug in. There should be sufficient slack on each side to allow for movement but without rubbing against or contacting anything.
    Passenger’s side:
    Driver’s side:
    
14. Once the wiring is adjusted, cable tie the newly installed exhaust valve cable in three places to the preexisting cable in the rear bumper and trim the excess cable tie.
    
15. Reinstall the rear black bumper panel.
    
16. Push the muffler up and forward then torque the clamps. If the muffler contacts any part of the car, twist the inlet pipes to adjust. Allow for the pipe clearances as pictured below.
    Torque Specifications:
    • Single-Bolt Inlet Pipe Clamps: 45 ft-lbs
    • Double-Bolt Muffler Clamps: 33 ft-lbs
    
17. Install all four tips, but do not secure them in place yet:
    • The inside tips should be flush with the rear bumper as pictured below.
    • The outside tips should be offset about ¾” from the inside tip.
    
18. After adjusting the tip length and alignment, make sure the second vertical line of the N in the Dinan logo is facing straight up on all 4 tips.
    
19. The exhaust tips should fit on both sides as pictured below. Torque the exhaust tip clamps to 45 ft-lbs.