Alfa Romeo Oil Cooler Replacements

Alfa Romeo Oil Cooler Replacements: A Vital Upgrade

The cooling system of any vehicle is paramount to its longevity and optimal performance. For Alfa Romeo owners, particularly those with the popular GTA and specific diesel models, the oil cooler system plays a crucial role. Unfortunately, original parts can be prone to wear, rust, and unavailability, leading to potential engine damage. Fortunately, specialist solutions are available to keep your beloved Alfa Romeo running smoothly. This article delves into the cost and benefits of replacement oil cooler kits for various Alfa Romeo models, focusing on the practicalities of fitting and the advantages of upgrading.

Understanding the Problem: Leaking and Rusted Pipes

Many Alfa Romeo models, including the 1.9 16V 147, 156, and GT diesels, are known to suffer from issues with their original oil cooler pipes. These pipes can succumb to rust and degradation over time, leading to significant oil leaks. Such leaks not only result in a loss of essential engine oil but, more critically, can lead to catastrophic engine failure if left unattended. The original oil cooler and pipe assemblies are, in many cases, no longer available from Alfa Romeo, leaving owners with a difficult decision. The situation is compounded for the petrol models, such as the 156 GTA, 147 GTA, GT 3.2, and 3.0/3.2 GTV, where original pipes also face availability issues and are notoriously difficult to replace, often requiring engine removal.

The Solution: Autolusso Replacement Oil Cooler Kits

Recognising these common issues, Autolusso has developed comprehensive replacement oil cooler kits designed to be a superior and more accessible solution. These kits are engineered to be a direct, bolt-on replacement, eliminating the need for complex pipe joining or modification of the original components. The kits are supplied with everything required for installation, and importantly, include a few extra components to account for any unforeseen fitting challenges or minor errors. A particularly useful inclusion is extra pipe, allowing for a 'dry run' of the pipe fitting, ensuring a perfect fit before final connections are made.

Diesel Model Kits (1.9 16V 147, 156, GT)

For the 1.9 16V diesel variants of the 147, 156, and GT, the Autolusso kit provides a complete solution. The original parts are no longer procurable from Alfa Romeo, making this aftermarket kit an essential replacement. The kit is designed for straightforward installation, with no pipe joining necessary. While a bracket is supplied, it's important to note that minor modifications may be required to ensure a perfect fit to the specific vehicle. The cost for the diesel kit, when fitted by Autolusso's trained technicians, along with an oil and filter change, is approximately £550 inc VAT. It is also recommended to perform an oil and filter change after a few minutes of running the engine post-installation to ensure a clean system.

Petrol Model Kits (156 GTA, 147 GTA, GT 3.2, 3.0/3.2 GTV)

Autolusso also offers a highly effective replacement kit for the petrol-powered GTA and GTV models. These kits are designed to address the original pipes' tendency to rust and the general unavailability of direct replacements. When original parts were available, they carried a significant price tag of around £750 inc VAT. In contrast, the Autolusso kit is priced at a much more accessible £220 inc VAT. Furthermore, the fitting process is considerably simpler. The original oil cooler pipes on these models often run up the back of the engine, making their replacement a labour-intensive task, potentially taking up to 8 hours and even requiring engine removal. Autolusso's kit, however, only necessitates the removal of the front bumper, and a competent technician can typically complete the installation in under 2 hours. It's worth noting that the 147 GTA GT 3.2 kit features a larger oil cooler, which can be fitted to the 156 GTA, although it may present a tighter fit. As with the diesel kits, an oil and filter change is recommended shortly after installation.

Fitting Guide: A Step-by-Step Overview

While professional fitting is recommended for peace of mind and warranty, understanding the process can be beneficial. The following outlines the general steps involved in fitting an Autolusso oil cooler kit:

Preparation and Removal of Old Components:

• Begin by removing the front bumper and the vehicle's undertray.
• Detach the plastic air duct by undoing the two trim clips and two bolts at the top.
• Locate and identify the old oil cooler, which may be saturated in oil.
• Identify the old oil cooler pipes, noting their tendency to rust and leak.
• Locate the oil cooler pipes connected to the oil filter housing. Undo the two Allen bolts securing these pipes.
• Prepare a suitable container to catch any draining engine oil when disconnecting the pipes from the oil filter housing.
• Undo the two bolts holding the old oil cooler to its bracket. Penetrating oil is advisable here to prevent the stud from snapping, which would complicate the removal.
• Once removed, you will be left with the original bracket.

Installation of the New Kit:

• The Autolusso kit includes a new oil filter housing and cooler bracket.
• The new bracket may require slight adjustment to align the bolt holes with the original mounting points. Modifications, such as cutting or drilling, might be necessary as indicated in fitting guides.
• Ensure the holes on the new bracket align correctly with the car's mounting points.
• Attach the new oil cooler to the adjusted bracket.
• Fit the dowty washer and screw in the new unions to the oil filter housing, tightening them securely.
• Drain the engine oil by removing the sump plug. It's advisable to do this while other tasks are being completed.
• Remove the heat shield from the oil filter housing (usually two bolts) to gain clear access.
• Unscrew the old oil filter. You may require a set of grips for this.
• Remove the centre bolt from the oil filter housing.
• Clean the oil filter housing thoroughly with a cloth or paper towel.
• Screw in the new centre bolt, ensuring the smaller side is inserted first.
• Lubricate the rubber seal on the new sandwich plate with a small amount of oil to ensure a secure seal.
• Fit the new sandwich plate over the centre bolt and secure it with the remaining section of the centre bolt.
• Lubricate the rubber seal on the new oil filter and screw it onto the sandwich plate until tight.
• Carefully measure and cut the new oil cooler pipes to the required length. It's recommended to cut the shorter pipe first, as extra pipe is supplied.
• To make fitting the rubber pipes onto the metal unions easier, immerse the ends in hot water from a recently boiled kettle until they become pliable.
• Push the softened rubber pipe firmly onto the metal union, ensuring it goes all the way to the end for a secure connection.
• Attach the appropriate fittings to the cooler and sandwich plate – typically 'right angle' connectors for the cooler and more angled connectors for the plate.
• Refit the plastic air ducts.
• Refit the sump plug with a new washer and refill the engine with the correct grade and quantity of engine oil. A useful tip for pouring oil is to do so upside down to ensure a smooth flow, allowing for air displacement.
• Start the engine and allow it to run for a few minutes, meticulously checking for any leaks around the new fittings and cooler.
• Finally, refit the front bumper. It might feel a bit snug, but it should fit correctly.

Important Fitting Considerations: What NOT to Do

Autolusso has observed instances where their oil cooler pipes have been fitted incorrectly, often using hose clips. This is strongly discouraged. The supplied fittings are designed for a secure, clamp-free connection. Using hose clips can damage the pipes and compromise the integrity of the seal, leading to leaks. Always ensure you use the provided fittings as intended.

Cost Comparison: Original vs. Aftermarket

The cost difference between original, if available, and aftermarket replacement oil cooler kits is substantial, especially for the petrol GTA models. While original parts could cost upwards of £750, the Autolusso kit offers a significantly more economical solution at around £220. For diesel models, the complete fitting service with an oil and filter change is £550, which is a competitive price considering the complexity of the issue and the parts involved.

Frequently Asked Questions

Q1: Why do Alfa Romeo oil cooler pipes fail?

The original pipes are susceptible to rust and degradation over time, particularly in certain environmental conditions. This weakening can lead to leaks and, ultimately, engine damage.

Q2: Are the Autolusso kits a direct replacement?

Yes, the Autolusso kits are designed as direct, bolt-on replacements. While some minor bracket adjustments might be needed for an optimal fit, no complex pipe joining or modifications to the core vehicle structure are required.

Q3: How long does it take to fit an Autolusso oil cooler kit?

For petrol models, a competent technician can typically complete the installation in under 2 hours. For diesel models, the quoted price includes fitting and an oil change, implying a similar timeframe.

Q4: Is an oil and filter change necessary after fitting the new kit?

Yes, it is highly advisable. Running the engine for a few minutes after installation and then performing an oil and filter change helps to flush out any residual debris and ensures the system is clean.

Q5: Can I fit the kit myself?

While the kit is designed for easier fitting, it does require mechanical knowledge and the right tools. If you are not experienced with car maintenance, it is recommended to have the kit fitted by a qualified technician to ensure correct installation and avoid potential damage.

Q6: Where can I find feedback on these kits?

Customer feedback and discussions regarding this modification can often be found on dedicated Alfa Romeo owner forums, such as www.alfaowner.com.

Conclusion: Investing in Your Alfa Romeo's Future

Addressing issues with the oil cooler system is not merely a repair; it's an investment in the long-term health and reliability of your Alfa Romeo. The availability of well-engineered, cost-effective replacement kits from specialists like Autolusso makes this essential upgrade more accessible than ever. By opting for a replacement kit, you not only mitigate the risk of severe engine damage but also ensure your Alfa Romeo continues to perform at its best, providing the thrilling driving experience it's renowned for.

Please note: Information regarding bracket design may be subject to updates. For the most current details and fitting assistance, contacting Autolusso directly on 01582 869560 (option 3) is recommended.

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