So over the past few weekends I have been in the process of installing my mods onto my 2012 JCW R58. All the engine bay stuff (Hot Side Boost Tube, Forge BoV, DoS Intake, BSH Oil CC, Seafoam Fogger, Boost taps, etc...) is completed. This past weekend I decided to dive into installing my Forge Intercooler. I lifted the car and started the process of removing the front bumper. Since my R58 has the same N14 engine as my R55 did, I assumed all would be the same. Once I got the bumper removed, I found something that didn't exist on my R55. A lower crash bar.



This lower bar is welded into place and as far as I can tell cannot be removed.

Here are some more shots:















The intercooler I have is the Forge R56 unit. I only used it for about 8000 miles on my R55 before I stripped it off when I sold the car. I guess I assumed it would fit considering the front end is identical. But I guess not. On the Forge Motorsport page they do list the R58 intercooler as a separate part number, but it looks identical to the R56 unit. Also the instruction manual for the R58 unit does not show images of this bar on their demo car, which is a euro spec MINI. Which makes me believe this is only on US cars or only on JCW cars.

I also have concerns, as I have found several vendors selling the R56 unit as compatible to the R58, and even listing the R58 JCW as compatible. I called Forge USA up and asked about it and they mentioned that they do not have a R58 intercooler for the US market available yet. So I am wondering if any of the vendors actually have installed an intercooler (Forge or otherwise) into a R58 or specifically a JCW R58. Maybe the Euro spec R58s do not have that lower crash bar, or maybe it is only on JCWs. I don't know. But I image that since the Forge won't fit, than the Helix and Alta will not as well. I can't really say about the Tyrolsport, but looking at their install instructions, their demo car does not have the lower brace and there is no mention of it in the directions. With theirs you need to remove the entire front bumper support, but even with that removed I can't say it would clear the lower crash bar.

If anyone has thoughts on this or if I missed some glaring thing with the install, please let me know. I forwarded these photos to Forge and will do so to the other manufacturers.

Thanks,

-Z

 

I have an N18....had to remove the crash bumper.

 

Nice! So how was that removed? I couldn't see where I could remove it. Is it welded to the bumper support above it and comes off with it? Is that the Forge or Helix?

 

It's the forge unit, you can see how close it is to the lower crash bar...can probably barely squeeze a quarter in between.

The lower one and upper crash bar all remove as one piece. I believe there are about 11-12 bolts holding it to the front end to the car...it all comes off as one piece.

The tricky part is putting it back on because the holes might not line up because of the weight of the engine bringing it down a tad. Easily done by just having a second hand push up a bit while you line up all the bolts and tighten it down.

 

This is great and terrible news! This means I have to take that damn bumper off again!!!

Seriously though, thanks. I will reference the Bentley manual and try this next weekend.

Thanks!

 

No problem! And yea that bumper is a pain, especially with the brake ducts...well at least for the S R58s it is haha.

It's actually the bolts that are marked with red paint that have to be removed...you can see them in the pictures you uploaded.

I don't have a Bentley manual....just jumped in and went for it. Next time you have it apart you'll see it's actually fairly straight forward.....but that Bentley Manual wouldn't hurt to have haha.

 

The Helix intercooler fits behind the crash bar with no issues.

 

But it still has to be removed in order to do the install...correct?

 

You def didn't try to install it correctly. I've already installed 6 of the Forge intercoolers on the R58's and R56's with that extra crash bar and they all fit perfect. You need to unbolt the bumper as that extra crash bar is part of the bumper and then install the intercooler on the mounts and hoses, then just bolt the bumper back on. You'll have just a little more than a 1/4 inch clearance between the crash bar and the intercooler.

 

Well I wouldn't say I didn't TRY to install the bumper correctly. Once I got the bumper off, the lower crash bar was something new to me, and ironically in none of the manufacturers instructions does it say this crash bar even exists. Even on the Forge's install instructions on the R58 is doesn't mention this. Thanks to NewCooperFanatic's post, it is clear that the full bumper support needs to be removed, which I never had to do before on my R55. So I did TRY to install it correctly, I just stopped once I got as far as where I knew to go. Now I know I need to go further. The point of me bringing this whole thing up was to get clarification of if I missed something (which I did) as well as inform others, as I was unable to find anything in the forums about fitment issues and the lower crash bar.

I will probably dive back into this tomorrow.

-Z

 

Yes, apparently this is the case. It all comes off as one piece I believe.

 

Just thought of something.

Instead of removing the whole crash bar, just back the bolts out enough so you can pull the whole crash bar towards you about an inch. You should be able to maneuver the FMIC into place.

Then just tighten everything back up.

.....should have thought of this about a year ago haha, the install would have went much quicker.

Then you won't have to worry about lining up the bolts like I mention in my earlier post.

Worth a try

 

Well I got it installed today. There was no way to just loosen the bolts and fit the Forge in there (as far as I could tell), so I just removed the entire bumper support. 6 - Front facing nuts, 2 - rear facing nuts, and 2 - T20 screws. The rear nut on the drivers side up by the brake duct was a ***** to get to with the wheel on. I image removing the wheel and the inner fender well would have made it not so painful. Getting them all to line up when reinstalling also was a chore but not too bad.

I could probably fit a piece a dental floss between the FMIC and the lower crash bar, but that's all. It's pretty tight for sure.

Glad it is finally on.

 

Here are a couple pics of the Forge intercooler installed on the last R58 we did.



You can see there is plenty of room between the bar and the Intercooler

 

Yea, there is definitely more room on the passenger side than on the drivers side. My gap on the drivers side looks identical to photo NewCooperFanatic posted earlier. It looks like you might have an extra 1/8" or so play than I do. I tried sucking the IC up as far as it goes, but it basically rests on the radiator so there isn't anymore room to go. Either way, it does fit. I assume the Helix would be the same?

 

Yea...I have no idea how you have that much room Way!

You can only bolt both left/right tabs so much. From what I remember there was really no extra movement to get more clearance.

t's all good though, no rubbing and has been working great for the past year...put it on about a week after I took delivery of the car.

At least you got it over with zcast haha.

 

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