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Do you have pics of where the leak is? The only place coolant goes through the front cover is straight back from the water pump, through the cover, intot the block. There's just a gasket between the pump and the cover, and I think just a gasket between the cover and the block. I belive the only O-ring on that face of the front cover is for the oil passage.
Have you tried torquing down the pump and cover 10mm nuts a bit to see if that helps?
On 2000s, oil in water after a head gasket change can be from lack of sealer around the drain-down area passages in the head gasket at the back of the head. New original Alfa gaskets have no sealer there, which you need to add for old (GTV era) blocks. Jon Norman marks the plastic wrap of his gaskets to show where to put sealer, but I don't know if other sellers do, or if aftermarket gaskets have the same issue.
Andrew Watry
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