How to install Police HD Oil Cooler

[rjkusse]

Mod:
Install Factory Policecar HD Oil Cooler

Time:
3 hours

Skill Level:
Medium - Hard

Tools Required:
-10MM
-7MM
-Vise Grips
-Wrench
-Pliers
-Dremel with cutoff wheel (optional)
-Serpentine belt tensioner bar (to remove the belt)
-Oil filter wrench
-Bucket

Additional required items:
-Oil filter and oil (if doing oil change)
-Antifreeze
-Thread-locker
-Radiator hose clamp (optional)

This weekend along with the Phenolic Spacers, I installed the Police HD Oil Cooler. Since there are no instructions, I thought I would try and throw something together to help everyone out.

In addition to the kit, you will need some antifreeze and now is a good time to change the oil, which I did, so a new filter and oil also.

The kit:



Oil filter mount, new thermostat housing, hose from thermostat housing to oil filter mount, new lower radiator hose.

Step 1: First thing is to get the car up and remove all the plastic covers from the bottom.



Step 2: Next drain the radiator using the drain cock on the passenger side.

Step 3: remove the filter and/or drain the oil if you are going to do an oil change at the same time.

Step 4: remove the filter pipe nipple that is in the block. Vise grips can be a man's best friend but they aren't very nice to parts.

Pipe nipple out:



Step 5: Install the new oil filter mount. I recommend using some thread locker on the end which goes into the block:



Step 6: Next remove the stock thermostat housing. I would not recommend installing the new one yet, it will help having this out of the way when trying to remove the stock lower hose.



Step 7: I also removed the drive belt to get to the lower hose and had to cut off the stock clamps since I was unable to get either of them off.

Step 8: Install the new lower hose. I found the clamp that was on the hose with the kit to be too small. I chose to cut it off and use a regular worm gear clamp. It seems the end of the new lower radiator hose is smaller than the stock one and with the clamp on it, it's nearly impossible to get it to fit the radiator. Maybe someone else has had a different experience.

Step 9: Once the new lower hose is in, reintall the drive belt.

Step 10: Now you can install the new thermostat housing. Now is a good time to install your new lower temp thermostat as well. I put in the 176 degree thermostat from Autozone (part #4127)





Step 11: Add the new bypass hose to the bottom of the new thermostat housing. Notice when installed, the clearance is tight. I used a tie wrap as added protection.



Step 12: With both hoses now at the new oil filter mount, connect the hoses.



Based on the orientation of the 2 hoses, it's almost impossible to mix up which one goes where.



Step 13: Install new oil filter, oil and coolant and put all the plastic back in. You will need to check the coolant level over the next couple of days to make sure it is back to the right level. Or, you can let the car warm up to operating temperature and then let cool down a couple of times. You need to get the thermostat to open so the coolant will run through the system before you can be sure about your coolant level.

[lafrad]

AWESOME.

GREAT Write up!

[Hemi31]

Nice write up......I think this is my next mod.

[feros]

I got a PM from formerice, a memeber here and he told me this....
when you do the police oil cooler, you pull off the oil filter and pull out the nipple that the filter screws onto and replace it with a longer one that comes with the kit, the cooler itself bolts on and the new longer nipple is there to screw the filter back on. Then you replace a couple water hoses and plumb to the oil cooler, refill antifreeze, and your done. The nipple is a [bugger] to remove. You will need the right size extractor, a good one not a Chinese pos or it will break off inside the nipple. After looking at the replacement nipple, it has blue loctite on it, so I decided to carefully heat it with a torch untill cherry red, bingo it unscrewed easily. If you do a search for police oil cooler, there is a breakdown of parts that you can get from a Mopar dealer. Beauty of this cooler is that it uses 180 degree antifreeze to cool the oil. Antifreese is way more efficient than air, next it allows heat from the oil to quickley heat up the antifreeze in the winter reducing friction.

I have the parts sitting in my garage waiting for me to get home in about 15 days from now to install.

[formerice]

Yes, I had a bitch of a time with the nipple until firing up the torch, bingo, that was the answer. I broke a cheap extractor off inside the nipple, before the torch and vicegrips. Good writeup.

[Fast56k]

Nice job with the pictures and all. I added this one to my vehicle.

C.

[feros]

Just did mine, and what a "bugger", I don't think there is enough bad words in the dictionary to describe all the ones I said. I know I have made up a few of my own along the way.
I even called a life line, it ended up being morale support, but it sure made me feel better!
I'll post pix in a bit.

[BrilliantBlackHemi]

Ok, so can some post the details of the part numbers you have to buy AND of the tool needed?

[lowriderman3]

Awesome writeup man!

[glhs837]

Another option for that nipple, for those who dont have a torch, is perhaps to get two nuts that fit, run one up a way, then the other. Back the first one back down so it jams up against the bottom one. This should let you get a big enough wrench on there.

[JonzMgnm]

Another option for that nipple, for those who dont have a torch, is perhaps to get two nuts that fit, run one up a way, then the other. Back the first one back down so it jams up against the bottom one. This should let you get a big enough wrench on there.

"Jamming" nuts is a great trick, but if I'm not mistaken the oil filter nipple is pipe thread. I'm not aware of pipe thread nuts.

[feros]

Finally a few pics of what it took to get that damn nipple out.

The braker bar!!!



The nipple


I think I tore it up a bit.

[feros]

Part numbers for Police Charger oil cooler

Police Engine Oil (Cooler) - 5037523AA – MSRP $ ???

Police Radiator Hose Lower - 4596561AC – MSRP $27.80
Police Radiator Hose Upper - 4596562AC – MSRP $39.45
Police Thermostat Housing - 53022168AA – MSRP $ ???

[FlyByU]

Found the hoses for $20 and $29 respectively. Cant find the other two parts.

[feros]

Ok, so can some post the details of the part numbers you have to buy AND of the tool needed?

I used a pipe easy out set, I had to use 3 seperate sizes and a hack saw once the end of the nipple split on me.

Even with that and that HUGE cheater bar, every time it turned it creeked like loosing a lug nut on a 65 Chevy that has been sitting in a junk yard that flooded every year since 66.

"Jamming" nuts is a great trick, but if I'm not mistaken the oil filter nipple is pipe thread. I'm not aware of pipe thread nuts.

Correct, jamming nuts would not work. There is nothing to grab onto in or on the top/bottom of the nipple.