D660-0098 Dinan Valved Axle-Back Exhaust
Product Information: Product Name: Dinan Performance Exhaust
System Model Number: D660-0098 / D660-0098-BLK Compatible Vehicle:
G42 M240i & xDrive Document Revision: C Release Date:
07/25/2023 Thank you for choosing the Dinan Performance Exhaust
System. This product has been meticulously developed by the Dinan
Engineering Team to provide increased performance, durability, and
an aesthetically pleasing design. It is designed for easy
installation and maintenance. Product Usage Instructions:
Removal of Stock System 1. Locate the factory cut points on
the stock exhaust system, which are indicated by dimples or punch
marks on the pipes. 2. Support and cut the stock exhaust at the
identified cut points. 3. Remove both stock tips and unplug the
exhaust valve. 4. Unbolt the exhaust hangers and remove the stock
muffler. Installation of Wiring Harness 5. Loosen the
passenger’s side panel in the muffler cavity and route the wiring
harness as indicated. 6. Remove the rear black panel by removing
the seven bolts. 7. Route the wiring through the clips in the back
bumper, above where the back panel mounts. 8. Loosen the driver’s
side panel and route the wiring as shown. Leave about 8 inches of
wiring length on this side. 9. Secure the driver’s side panel back
in place. Adjust the cable length if necessary. 10. Ensure that the
muffler cavity looks as pictured in the instructions.
Installation of Exhaust Valves 11. Attach the actuators,
brackets, and springs to the Dinan exhaust valves using the
provided hardware. Follow the diagrams provided. 12. Make sure that
the spring is always under pressure between the actuator and the
exhaust valve. If the spring fits loosely, spread the ends apart as
needed to ensure proper compression during installation.
Installation of Inlet Pipes 13. Install the hangers onto the
inlet pipes and then install the inlet pipes. 14. Loosely tighten
the clamps but do not fully torque them yet. Please note that if
you feel you do not have the necessary skills or tools for the
installation, it is recommended to seek assistance from a qualified
repair facility. If you encounter any difficulties during the
installation or if the instructions are unclear, please contact
Dinan’s Technical Support Staff at (800) 341-5480. Thank you for
choosing Dinan! Enjoy your Dinan Performance Exhaust System.
Install Instructions
Installation Instructions
D660-0098 / D660-0098-BLK EXHAUST SYSTEM
G42 M240i & xDrive
Document Revision: C Release Date: 07/25/2023
Table of Contents
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.
Removal of Stock System ……………………. 2 Installation of Wiring Harness ……………….. 3 Installation of Exhaust Valves ……………….. 7 Installation of Inlet Pipes ……………………. 9 Installation of Dinan Muffler………………… 10
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.
INS660-0098(-BLK)
Page 1
Install Instructions
Removal of Stock System
1) Support and cut the stock exhaust at the factory cut points. The locations are indicated by a dimple or punch mark on the pipes.
Sample dimples
2) Remove both of the stock tips and unplug the exhaust valve.
Unbolt both tips
3) Unbolt the exhaust hangers and remove the stock muffler.
INS660-0098(-BLK)
Page 2
Install Instructions
Installation of Wiring Harness
4) Loosen the passenger’s side panel in the muffler cavity and route the wiring as indicated below.
Remove these three bolts
Route the wiring under this panel here
INS660-0098(-BLK)
Page 3
5) Remove the rear black panel. Remove these seven bolts
Install Instructions
INS660-0098(-BLK)
Page 4
Install Instructions 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.
INS660-0098(-BLK)
Page 5
Install Instructions 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.
INS660-0098(-BLK)
Page 6
Install Instructions
Installation of Exhaust Valves
10) Following the diagrams below, attach the actuators, brackets, and springs to the Dinan exhaust valves using the hardware provided.
INS660-0098(-BLK)
Page 7
Install Instructions
For proper operation, the spring must always be under pressure between the actuator and the exhaust valve. If the spring fits loosely, please spread the ends apart as needed, so that the spring is compressed during installation.
INS660-0098(-BLK)
Page 8
Install Instructions
Installation of Inlet Pipes
11) Install the hangers onto the inlet pipes and install the inlet pipes. Loosely tighten the clamps, but do not fully torque yet.
INS660-0098(-BLK)
Page 9
Install Instructions
Installation of Dinan Muffler
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:
INS660-0098(-BLK)
Page 10
Driver’s side:
Install Instructions
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.
INS660-0098(-BLK)
Page 11
15) Reinstall the rear black bumper panel.
Install Instructions
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
INS660-0098(-BLK)
Page 12
Install Instructions 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. · Dinan recommends offsetting the tips, but this is up to the customer.
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.
INS660-0098(-BLK)
Page 13
Install Instructions 19) The exhaust tips should fit on both sides as pictured below. Torque the exhaust tip clamps to 45 ft-lbs.
INS660-0098(-BLK)
Page 14
