Oil coolers

Autolusso have made a replacement oil cooler kit, that is cheaper and easier to fit ,for the156 GTA, 147 GTA, GT 3.2 and 3.0 / 3.2 GTV models. There is also a new kit at Autolusso that fits the 1.9 16V 147,156, GT and 2.4 20V diesel models.

The kit comes with everything you need to fit it, along with a couple of extras in case you make a mistake. We include extra pipe so you can have a dry run at fitting the pipes.

Diesel kit (1.9 16V 147, 156, GT)

The 1.9 16V 147, 156 and GT diesels all suffer with the oil cooler pipes leaking and / or rusting, causing engine failures. The only solution to this is to replace all of the oil cooler and pipe assembly.

The original oil cooler and pipes are no longer available from Alfa Romeo. However, our kit is now available. This is a complete bolt on kit with no joining of pipes required.

We can supply a bracket with our kit but it does require some slight modification in order to make the kit fit to the car. The images below show the older kit.

This is available on our shop or we can have one of our highly trained technicians fit the kit for you with warranty and an oil and filter change for £550 inc VAT.

It is advisable that, once the kit is fitted, to run the engine for a few minutes then carry out an oil and filter change.

Remove the bumper and undertray.	Remove the plastic air duct but detaching the two trim clips and two bolts at the top.	The old oil cooler fitted to the car (this can often be saturated in oil).	The old oil cooler pipes fitted on the car. These tend to rust and rot away causing oil to leak out.
The old oil cooler pipes fitted to the oil filter housing on the car.	Undo the two Allen bolt that holds the pipes to the oil filter housing.	When removing the old pipes from the old oil filter housing, havea container ready to catch the oil that drains out.	Undo the two botls holding the cooler ot the bracket. Penatrating oil is a good idea here, as if the stud snaps its part of the cooler.
The oil cooler has been removed and you are left with the bracket on its own.	The Autolusso oil cooler replacement kit including the new oil filter housing and cooler bracket.	The bracket will need adjusting slightly to ensure that the bolts line up with the holes. We have marked out on where you will need to cut in order to make it fit.	You can try and fit a blade in between the gaps but we find it is easier and quicker to drill in between.
All done and ready to be fitted.	Make sure that the holes line up with the old bracket.	Attach the new bracket to the oil cooler.	Fit the dowty washer and screw in the unions to the oil filter housing and tighten.
Make sure you have a container ready and remove the sump plug and drain out the engine oil.	Whilst the engine oil is draining, you can remove the heat shield from oil filter housing (2 bolts).	Once you have removed the heat shield, you will have clear access to unscrew the oil filter (you may need a set of grips for this).	Once the filter is removed you will need to remove the centre bolt from the housing.
Once removed, use some form of cloth, rag, paper towel to clean up the housing.	Screw in the new centre bolt, ensuring that the you inserting the smaller side first.	Rub a small amount of oil round the rubber seal as this will help create a secure seal against the housing.	The new sandwhich plate will fit over the top of the bolt and you can secure using the other section of the centre bolt.
Like the rubber seal on the sandwich plate, we advise doing the same to the oil filter and screwing it on until tight.	Measure the length of pipe carefully and cut to size. We do supply a small amount of extra pipe so we advise cutting the smaller pipe first.	Boil a kettle and fill a large mug or jug with hot water and insert the rubber pipe in the water until it is soft enough to push ove the metal union. Chocolate disgestives are optional.	Ensure you push the pipe right up to the end.
Attach fittings to the cooler and sandwich plate. Use the 'right angle' connectors on the cooler and the more slanted connectors for the plate.	Refit plastic air ducts	Refit sump plug and washer and refill engine oil. Top Tip: When pouring oil always pour it upside down as this will come out smooth as it accounts for air displacment.	Once the engine oil has been filled up leave the car running and check for leaks. Then refit bumper (it may be a bit tight but it does fit).
Refit front bumper, refit wheels and enjoy!

DO NOT FIT YOUR OIL COOLER PIPES LIKE THIS

We have seen many people fit our coolers using hose clips (pictured to the right), this is not the right way of doing this as the clips are not required. This can damage the cooler pipes and cause them to leak.

*The oil cooler brackets have been superseded by a newer more robust part. For help with fitting please call us on 01582 869560 (option 3)*

Petrol kit (156 GTA, 147 GTA, GT 3.2 and 3.0 / 3.2 GTV)

Autolusso have made a replacement oil cooler kit to fit 156 GTA, 147 GTA GT 3.2 and 3.0 / 3.2 GTV.

The kit comes with everything you need to fit the kit and a couple of extras in case you make a mistake. We include extra pipe so you can have a dry run at fitting the pipes.

The original pipes suffer from rust and are mostly unavailable. Original pipes and cooler when they were available from Alfa Romeo were approximately £750 inc VAT, but our kit is £220 inc VAT and much easier to fit. The original oil cooler pipes run right up the back of the engine and are incredibly difficult to change without removing the engine (approximately 8 hours to fit). Our kit requires the removal of the front bumper, and a competent technician should take no more than 2 hours to complete the job.

It is advisable to run the engine for a few minutes once the kit is fitted, then carry out an oil and filter change.

The 147 GTA GT 3.2 kit has a larger oil cooler. This can also be used on the 156 GTA but it is very tight fit.

*The bracket has changed since this fitting guide was first produced*

Feedback

If you would like to see any of the feedback from customers who have had this particular modification done to their Alfa Romeo you can find it here: www.alfaowner.com