Removing and installing/replacing right charge air duct (B48 and B46 engine) (Cooper S and John Cooper Works)

Safety instructions: 

• In the event of a leak at the pressure pipe, there is a risk of damage  on the exhaust turbocharger!

Preliminary work needed: 

• Remove front UNDERBODY PROTECTION .
• Remove THRUST FIELD .
• Remove FRONT RIGHT WHEEL ARCH PANEL .
• Release FRONT LEFT WHEEL ARCH PANEL at bottom.

Removal: 

Release screws (2) for front left cross connection.

Drill out blind rivets (1) for front left cross connection.

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Release screws (2) for front right cross connection.

Drill out blind rivets (1) for front right cross connection.

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Release front left and right locking pins (1) and remove locks (2).

Remove cross connection (3).

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Loosen screws (1).

Unclip line (2).

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Unlock lock of charge air cooler on both sides by means of suitable tool.

Detach charge air duct (1) from exhaust turbocharger.

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Unlock lock (1) of exhaust turbocharger on both sides by means of suitable tool.

Detach charge air duct (2) from exhaust turbocharger.

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Slightly pull right deformation element (1) downwards.

Feed out lower part of charge air duct (2) inside the marked area downwards.

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Feed out upper section of charge air duct (1) inside the marked area along the side member.

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Remove charge air duct (1) through the wheel arch.

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Preparation for installation: 

Check sealing lip (1) for damage.

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Installation note: 

Check that the seal (1) is fitted correctly:

The seal (1) appears to be fitted correctly in the pressure pipe.

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Installation note: 

Check that the seal (1) is fitted correctly:

The seal (1) appears to be fitted incorrectly  in the pressure pipe.

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Installation: 

Remove charge air duct (1) through the front right wheel arch.

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Feed in upper section of charge air duct (1) passing the side member.

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Feed in lower part of charge air duct (2) inside the marked area.

Push right deformation element (1) upwards into initial position.

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Release locks (1) from holders.

Locks must engage.

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Connect charge air duct (1) to exhaust turbocharger until lock (2) engages on both sides.

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Connect front right charge air hose (1) and lock.

Charge air hose (1) must audibly engage on charge air cooler.

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Tighten down screws (1).

Tightening torque: 11 00 2AZ .

Clip in line (2).

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Install cross connection (3).

Install locks (2) and lock with locking pins (1).

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Replace screws (2) for front right cross connection and tighten.

Tightening torque 17 10 9AZ .

Replace blind rivets (1) for cross connection and rivet.

Parts:  Replace blind rivets (1).

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Replace screws (2) for front left cross connection and tighten.

Tightening torque 17 10 9AZ .

Replace blind rivets (1) for cross connection and rivet.

Parts:  Replace blind rivets (1).

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Required follow-up work: 

• Install FRONT RIGHT WHEEL ARCH PANEL .
• Install the LEFT FRONT WHEEL ARCH TRIM PANEL .
• Install THRUST FIELD .
• Install front UNDERBODY PROTECTION .
• Check turbocharging path for leak tightness.
• Check function of DME.