Hello, first post here.
I found your group when looking for the front end service(maintenance) mode, and was very happy to see that there is a lot of great knowledge in here.

Spoiler, it was tight but I did not need to move the front end forward to get in there.

So here we go, wall of text but if you only have 3 minutes, skip to the youtube link at the bottom.

Note: I am based in Sweden and gave prices in Euros € which is about 1:1 with the US Dollar.



Overview, new pipe and original pipe. Fault area circled


Worn right through by the clip that was folded over

Edge of the clip that was folded over from the production line?

2014 Mini Cooper Countryman SD Diesel

(R60). Coolant pipe leak and replacement.



I booked the car into the dealer that sold it from new and has always serviced it to see if they could find the leak, I suspected the Y-pipe but could not be sure, I asked them to investigate if there were any technical bulletins or known cases of leaks in the Y-pipe area.



They said it was not a known issue and after inspection they couldn't find exactly where it was leaking either and would need to remove a lot more parts to find it, so that was 200€ wasted.



They quoted another 800€ (minimum) to continue with the repair (replace the Y-pipe) but could not guarantee if that was the only

fault and it could cost more.



So I ordered the pipe (100€) and decided to have a look at it myself.



4 hours later the fault is found and pipe replaced.



Before we start:

The car was bought new from the dealer and has never had anything other than normal services performed, no major work ever done in other words.





The fault was the plastic clip that holds the Y-pipe to the inlet manifold/throttle body(?) it was doubled over on the inside edge, most likely this occurred when the car was built in the factory, and after 9 years of vibration, the edge of the folded over clip wore through the y-pipe.

You can see it in the video and pictures.



Disclaimer, I am an experienced race car mechanic with 40 years of experience, but jobs like this are still daunting for me as I am very cautious and like to know what I am doing before I begin a job.



There are many electrical connectors that need to be carefully removed and bagged to stop dirt getting in, be extra careful with the pins on the engine control unit for example.

Many hose connections which I have not detailed, so google them before trying to release, ESPECIALLY the intercooler hose attachment as that was a tricky one.

The coolant that was released while doing the job was collected in a tray and disposed of correctly.

Clean everything and use new seals etc.

 

Nice, we dont get the SD or any diesel MINIs here in the USA.