6 Pass Oil Cooler Kit, with Barbed Fittings

Product Overview

Keeping your air-cooled engine running within its optimal temperature range is critical for longevity and performance, and the EMPI 6 Pass Oil Cooler Kit is the ultimate insurance policy for your Volkswagen. In an engine where oil does double duty as both a lubricant and a primary cooling agent, standard stock setups often fall short when faced with modern traffic, high-performance upgrades, or scorching summer heat. This kit provides a massive increase in cooling surface area, utilizing a 6-pass design that ensures your oil has ample time to shed heat before returning to the case. Whether you are cruising a heavy Westfalia through the mountains or pushing a high-compression Beetle on the highway, this kit offers the thermal stability you need to prevent oil thinning and premature bearing wear. It is a vital upgrade for any enthusiast who understands that heat is the number one enemy of the VW flat-four engine.

What sets this EMPI kit apart is the advanced mechanically expanded construction of the core. Unlike inferior coolers where the cooling fins are simply pressed loosely against the tubes, EMPI physically stretches the 1/2-inch copper tubing from the inside out during manufacturing. This process creates a perfect, high-tension metal-to-metal bond between the tube and the aluminum fins, maximizing heat transfer efficiency while maintaining a minimal pressure drop. The kit is a comprehensive cooling solution, arriving with a remote oil filter bracket and a bypass adapter, allowing you to move your filtration away from the engine heat and add much-needed oil capacity to your system. Don''t settle for mediocre cooling when it comes to your engine''s vitals; equip your VW with a professional-grade system designed to handle the rigors of the road and the trail alike.

Vehicle Fitment

• VW Type 1 Beetle / Bug: All models through 1974.
• VW Type 2 Bus / Transporter / Kombi: All models through 1971.
• VW Type 3 Squareback / Fastback / Notchback: All models.
• VW Karmann Ghia: All models.
• VW Thing: All models.
• Dune Buggies and Sand Rails: All models utilizing Type 1 upright engine configurations.

Technical Specifications

• Cooler Type: 6-Pass High-Efficiency Design.
• Core Material: 1/2-inch Copper Tubing with Aluminum Cooling Fins.
• Construction: Mechanically expanded for maximum thermal conductivity.
• Fittings: 1/2-inch Barbed Ends for secure hose attachment.
• Dimensions: 10 inches Wide x 7-1/2 inches Tall x 2-1/4 inches Deep.
• Bypass Adapter: Includes EMPI 9203 Oil Filter Bypass.
• Hose Type: Includes EMPI 9210 High-Temperature / High-Pressure Hose.
• Filtration: Includes Remote Oil Filter Bracket (Filter sold separately).
• Hardware: Full installation kit including necessary fittings and mounting hardware.

Pro Tips from the Master Tech

Strategic Mounting for Maximum Airflow

When installing your 6-pass cooler, placement is everything. For the best results in a Beetle or Ghia, many builders mount the cooler under the rear luggage tray area or over the transmission where it can catch "dirty" air moving under the car. However, if you are looking for maximum efficiency, consider mounting it with a dedicated air scoop or in a location that receives direct, high-velocity airflow. Always ensure the cooler is rubber-isolated if you are mounting it directly to the chassis to prevent vibration fatigue from cracking the copper solder joints over time. Never mount the cooler in a location where it is completely shielded from moving air, as it relies on convection to shed the heat it has pulled from your oil.

Mastering the Barbed Fitting Connection

This kit utilizes 1/2-inch barbed fittings, which are excellent for reliability when installed correctly. When sliding your high-temperature hose over the barbs, a small drop of clean engine oil on the fitting can help the hose seat fully against the shoulder. Always use high-quality stainless steel T-bolt clamps or heavy-duty worm-gear clamps, and ensure they are positioned behind the barb''s largest diameter to lock the hose in place. Double-check your hose routing to ensure there are no sharp bends or "kinks" that could restrict oil flow. A restricted return line can cause a spike in oil pressure that might damage your seals or even the cooler core itself. Secure the hoses every 12 to 18 inches with insulated P-clamps to prevent them from rubbing against the frame or engine tin.

Accounting for Increased Oil Capacity

One of the "hidden" benefits of adding a 6-pass cooler and a remote filter is the increase in total oil capacity. After you have completed the installation, remember that your engine will now require significantly more oil than the factory-specified amount. Before your first start-up, fill the remote oil filter with fresh oil to prevent a "dry start" and minimize the time it takes for the system to reach full pressure. Once the engine is running, let it reach operating temperature so the oil circulates through the entire 6-pass core, then shut it down and wait a few minutes for the oil to settle. Re-check your dipstick and top off as necessary. You will likely find you are running an extra quart or more, which in itself helps keep oil temperatures lower by increasing the total thermal mass of the lubricant.