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Discussion Starter #1
Hi all.
I recently took my Alfa 159 2.4jtdm into Halfords auto for a full air conditioning service. However, the guy discovered a hole in the pipe that runs just under the plastic engine cover down to the front of the engine toward the radiator which meant he could not carry out the service. He suggested that it could be a big job as it may require the front of the car to come off! I'm no mechanic so could anyone shed some light on how big a job this could be?
Cheers
Flydan
 

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It is quite a big job, but you can do it through the under tray without removing the bumper, though it is awkward.

Trim the underside of the cover where it has worn through the pipe!

You need to remove the scuttle panel at the wipers too if it's the pipe I think.
 

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It depends which pipe it is.

I did this a few year ago on my 1.9jtdm 159. The hole was in the pipe that is made up of alloy and has a rubber flexi section in it. The joint between the flexi and the alloy had rotted, letting the coolant out. This was a pain to replace, but didn't need the bumper off. The part was around £134 from Alfa. Took us 30 mins to fit. The unions are snap on pressure joints. We just had to make sure the washer was replaced on the union between the pipe and the compressor.

But, the next problem did need the front bumper off! Looking through the lower grill of the bumper you can see a small section of pipe with a joint. The washer in the joint had gone, leaking.

So it was a bumper off. Easy enough, just time consuming.

I would take it to a specialist though, I use a great one in Birmingham.
 

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Discussion Starter #5
Cheers for the advice guys.
How come these things always seem to happen when you have much better things to spend money on?!
 

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and here i thought i was the only one, mine had a hole in the same place as yours, as cj said it is possible without taking off the bumper but its just a pain in the neck, litterally, anyways took me almost all day to change it
 

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on a side note, i had my hole welded up and made thicker so that it doesnt scuff through or whatever happened in the first place, worked like a charm and cost me a fraction of a new pipe system
 

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Discussion Starter #8
I was thinking about having it welded up myself so good to hear you've had success with it. I'll see what Mclennans here in Edinburgh have to say on tuesday.
 

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whether it can be welded up or not obviously depends on the size of the hole but if its a fairly standard scuffed through hole then it can be welded, i hope you come right! :thumbs:
 
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