Replacement Sand Seal Assembly, Fits EMPI Brand Pulleys

Overview

Protecting your air-cooled engine''s internal components from the harsh elements of the trail or dunes is paramount for any serious enthusiast. The factory Volkswagen design utilizes a spiral oil slinger on the crankshaft pulley to keep oil inside the case, but this setup offers virtually zero protection against incoming contaminants like fine sand, silt, or dust. This EMPI Replacement Sand Seal Assembly is the professional-grade solution for those running an EMPI sand-sealed pulley system. By providing a positive, physical barrier between the outside world and your engine''s main bearings, this assembly ensures that abrasive particles stay where they belongoutside. Whether you are rebuilding a high-performance street engine or maintaining a hard-working off-road machine, keeping your sand seal in top condition is the cheapest insurance policy you can buy against premature engine wear and catastrophic failure.

This specific replacement kit is designed for a precision press-fit into the engine case and is engineered to work seamlessly with the machined hub of an EMPI sand-sealed pulley. Over time, heat cycles and environmental exposure can cause the rubber sealing lip to harden or the metal collar to lose its tension, leading to oil leaks or, worse, the ingress of grit. This assembly includes both the high-quality rubber seal and the heavy-duty metal collar, allowing you to refresh your sealing system without having to purchase an entirely new pulley. It is a critical component for Baja Bugs, sand rails, and any Type 1 based vehicle that spends its life in high-dust environments. Don''t let a worn-out five-dollar part ruin a multi-thousand-dollar long block; upgrade to a fresh EMPI seal and keep your oil in and the sand out where it belongs.

Fitment

• VW Type 1 Beetle: All years equipped with an EMPI sand-sealed pulley.
• VW Type 1 Karmann Ghia: All years equipped with an EMPI sand-sealed pulley.
• VW Type 2 Bus / Transporter: 1200cc, 1500cc, and 1600cc upright engines (up to 1971).
• VW Type 3 Squareback, Fastback, Notchback: When converted to an upright cooling configuration or sand-sealed pulley.
• VW Thing (Type 181): All years.
• Custom Applications: Sand rails, Dune Buggies, and Baja Bugs utilizing Type 1 air-cooled engines.
• Compatibility Note: Specifically designed to fit EMPI brand sand-sealed pulleys; may not be compatible with other brands like Scat or Gene Berg without verification.

Technical Specifications

• Part Number: 00-8695-0
• Brand: EMPI
• Component 1: High-temperature Nitrile rubber seal with internal tension spring.
• Component 2: Precision-machined steel carrier collar.
• Seal Type: Single-lip positive contact sand seal.
• Installation Method: Press-fit into the engine case (requires machining of the case if not already equipped).
• Pulley Requirement: Must be used with a sand-seal specific pulley (machined hub).
• Weight: Approximately 0.11 lbs.
• Finish: Corrosion-resistant coating on the metal collar.

Pro Tips from Appletree Auto

Tip 1: Surface Preparation is Critical

Before pressing your new EMPI sand seal into the engine case, ensure the bore is absolutely clean and free of burrs or old sealant residue. We recommend using a light film of Curil T or a similar non-hardening case sealant on the outer diameter of the metal collar before installation. This helps ensure a leak-proof fit between the collar and the magnesium or aluminum case. When pressing the seal in, always use a dedicated seal driver or a large socket that matches the outer diameter of the collar to avoid distorting the metal or damaging the rubber lip. If the collar goes in crooked, it can lead to immediate leaks or uneven wear on your pulley hub.

Tip 2: Lubricate the Lip Before First Start

Never install a sand seal dry. Before you slide your EMPI pulley into place, apply a generous amount of high-quality assembly lube or clean engine oil to the rubber sealing lip and the polished hub of the pulley. If the seal is run dry during the initial startup, the friction will generate excessive heat, which can "glaze" the rubber or even melt the lip, rendering the seal useless within minutes. A properly lubricated seal will break in gradually and create a long-lasting, airtight bond with the pulley. Also, check the pulley hub for any nicks or scratches; if the hub isn''t perfectly smooth, it will act like sandpaper and destroy your new seal instantly.

Tip 3: Monitor for "Seal Grooving"

If you are replacing a seal because of a persistent leak, take a close look at the hub of your EMPI pulley. Over thousands of miles, the sand seal can actually wear a physical groove into the metal of the pulley hub. If you feel a distinct ridge with your fingernail, simply installing a new seal may not solve the leak, as the new lip won''t be able to seat into that deep groove perfectly. In some cases, you can slightly shim the pulley or the seal to move the contact point to a fresh surface, but if the groove is deep, it is time to replace the pulley along with the seal to ensure your engine stays bone-dry and protected.