Audi Engine Oil Cooler - Mahle/Behr 078117021A

Product Information

An engine oil cooler is a heat exchanger designed to assist in maintaining stable and adequate oil temperatures to prevent oil breakdown under heavy load conditions. It works by circulating engine oil through a series of small heat conductive passages that are exposed to either airflow (air to oil type) or coolant (water to oil type), depending on the design. Good quality synthetic oil begins to lose protection and lubrication properties generally around 300F and breaks down completely before 500F. In situations where the oil may be approaching this temperature range, it's crucial to bring it back down to standard operating levels.

In an air-to-oil cooler, good airflow is required to ensure the heat is effectively vented. In water-to-oil coolers, engine coolant flowing to the radiator is used to cool the oil. This does not require any additional ducting or fans, which makes this design increasingly popular with carmakers due to additional benefits in engine bay packaging.

Engine oil coolers typically have a thermostat built into the oil cooler circuit that opens and closes depending on the temperature of the oil, to avoid overcooling when temperatures are in a good range.

Engine oil coolers can fail for a few reasons, most commonly due to leaks, blockages, or physical damage. For air-to-oil coolers, the most common failure mode is physical damage caused by road debris or age/rust. Water-to-oil coolers have a different issue. Internal failure can cause coolant to mix with the oil, which will cause a milkshake-like consistency in the oil similar to a blown head gasket.

• External Leaks: Air-to-oil coolers are exposed to difficult road conditions and can be vulnerable to damage from rocks or other road debris.
• Age/Corrosion/Rust: Due to the harsh exposure to the elements, engine oil cooler lines are susceptible to increased levels of corrosion or rust, especially at the fittings. If bad enough, the fittings can become corroded enough to leak, or at minimum lose the ability to service the oil cooler
• Internal failure: Water-to-oil coolers are susceptible to internal failure, which can result in the engine coolant mixing with the engine oil. If gone unnoticed, this can result in engine failure, so it is important to regularly observe coolant or oil quality to ensure the oil cooler is in good shape, especially in older, higher-milage vehicles. Mixing water and oil will result in a “milkshake” style appearance in the fluid.
• Exterior seal leaks: When replacing a water-to-oil style cooler, it is critical to also replace the seals to avoid oil or coolant leaks upon reassembly. These seals can leak either oil or coolant depending on age, mileage, and heat cycling.

About Mahle Behr

Mahle Behr GmbH & Co. KG is a German corporation active in the automobile industry, headquartered in Stuttgart-Feuerbach. It is a specialist for automotive air conditioning and engine cooling systems. Mahle began in 1920 when pistons made of heavy gray cast iron were being used in internal combustion engines for automobiles and there was a need for a new design. The Mahle brothers countered this trend by producing light-alloy pistons at their small, newly established company however the technology was still finicky and problems come up frequently. They soon determined that they needed to come up with a solution to keep dirt and dust out of the engine so they eventually developed air and oil filters as well. Their perseverance paid off and the light-alloy pistons began to take over the market. Today, half of all automobiles produced worldwide contain MAHLE components. MAHLE offers an extensive range of parts for everyone including pistons, cylinder liners, piston ring sets, bearings, assemblies, valves, valve train components, and air, oil, fuel, and cabin air filters. Their catalog and online database of aftermarket engine components is an indispensable reference.In early 2016, Stuttgart-based MAHLE GmbH increased its holding in the Behr Group from 36.85 percent to approximately 51 percent with the acquisition of all shares in the BWK GmbH holding company. The company now goes by Mahle-Behr.