Hi,

I'm in the process of replacing the Crossover Pipe on my Wife's 2009 R55 Clubman Non-Turbo. I watched several videos on the process, but they were all on the Turbo Model. I found it impossible to remove water pipe with intake manifold installed. The transmission linkage was in the way, and there didn't seem to be enough room.

The Intake manifold on Non-turbo is slightly different design, and throttle body attaches on the passenger side close, above water pump for reference.

There is a bracket on the back of the intake that is difficult to see. I tried with a bore scope, and mirror. I could feel the bolt, but it was obscured by wires. I removed it from underneath the car with long extension.

I accidentally cracked the Crankcase breather hose, and I'm waiting on parts to finish, but I wanted to share my experience if people are doing this job on Non-Turbo.

I'm doing the same job on my non-turbo 2013 R58 Coupe, and the N16 engine is essentially the same as yours with regards to dealing with that fragile crossover water pipe. I'll be replacing that brittle plastic pipe with a proper metal pipe from ECS. I cracked the crankcase breather hose as well while trying to get the VANOS solenoid out; I was very surprised to see how un-flexible this hose is (or was). I've a new hose on order from ECS.

I'm struggling to get that bolt out that's underneath the intake manifold. I'm going to try going through the wheel well side tomorrow.

I ended up removing the intake manifold and fuel rail anyway. Then it was a cinch to install the metal crossover pipe with a new thermostat; bolting in the thermostat fully seats the crossover pipe on both ends:

+1^^

That cross over pipe looks good

It does look good. I do have two comments for ECS:

1. It's a shame that the ECS logo was imprinted on the other side of this pipe, as you can see it is invisible in its installed location, and
2. It may well be an academic issue anyhow, as it will be invisible to just about anyone who wouldn't be removing the intake manifold, which would be the only way to get this view of the excellent finish and build quality of this pipe.
   

Thanks for the input. Yep its hard to even see the pipe.

Glad to have this metal pipe option.