EMPI Super Stock 1600 Engine Kit

OVERVIEW

The EMPI Super Stock 1600 Engine Kit is the definitive solution for the air-cooled Volkswagen enthusiast who demands more than just a standard rebuild. This comprehensive long block kit is engineered to provide a significant boost in horsepower and torque while maintaining the legendary reliability that made the 1600cc dual-port engine a global icon. By utilizing a brand-new, high-quality Magnesium AS41 engine case as the foundation, EMPI has ensured that this engine provides superior heat dissipation and structural integrity compared to aged, line-bored recycled cases. Whether you are revitalizing a classic Beetle or powering a custom sand rail, this kit represents the perfect intersection of modern metallurgy and vintage performance, delivering a crisp throttle response and a smoother power band that makes daily driving an absolute joy without sacrificing fuel economy.

What sets the Super Stock 1600 apart is the meticulous selection of premium internal components that go far beyond standard replacement grade. Every kit features forged chromoly I-beam rods and a 69mm direct-drilled crankshaft for a rotating assembly that is built to handle higher RPMs and increased stress. The inclusion of dual-port cylinder heads equipped with stainless steel valves, hi-rev springs, and chromoly retainers ensures that your valvetrain is as robust as the bottom end. Complemented by a Schadek 26mm oil pump for superior lubrication and an Elring gasket set for a leak-free seal, this kit provides everything needed to assemble a professional-grade long block. When you choose the EMPI Super Stock 1600 from Appletree Auto, you aren''t just buying parts; you are investing in a precision-engineered power plant designed to keep your VW on the road for decades to come.

FITMENT

This engine kit is designed for Type 1 based air-cooled engines and is compatible with the following models:

• Volkswagen Beetle: 1966-1977 (Sedan and Convertible)
• Volkswagen Super Beetle: 1971-1979
• Volkswagen Karmann Ghia: 1966-1974
• Volkswagen Type 2 Bus: 1963-1971 (With Type 1 Upright Engine)
• Volkswagen Thing (Type 181): 1973-1974
• Custom Applications: Ideal for Dune Buggies, Sand Rails, Trikes, and Kit Cars using a Type 1 VW transaxle.

SPECS

• Engine Case: Brand New High-Quality Magnesium AS41 Dual Relief
• Crankshaft: 69mm Stroke, Direct Drilled, 4-Dowel Design
• Connecting Rods: Forged Chromoly I-Beam
• Pistons/Cylinders: 85.5mm Stock Diameter Set
• Camshaft: Stock Profile, .334 Lift / 250 Duration
• Cylinder Heads: Dual Port with Stainless Steel Valves
• Valvetrain: Hi-Rev Springs and Chromoly Retainers
• Pushrods: 4130 Chromoly, .375 Diameter, .080 Wall Thickness
• Rockers: Heavy Duty Solid Shaft 1.1:1 Ratio with Swivel-Foot Adjusters
• Oil Pump: 26mm Schadek High-Volume Pump
• Head Studs: 8mm Chromoly for Superior Clamping Force
• Bearings: Silverline Main Bearings and Double Thrust Cam Bearings
• Flywheel: Stock Style 4-Dowel with Chromoly Gland Nut
• Gaskets: Genuine Elring Gasket Kit and High-Quality Main Seal
• Hardware: Complete set of lifters, valve covers, and pushrod tubes included

PRO TIPS

1. Prioritize Cleanliness and Pre-Assembly Inspection

As a specialist, I cannot stress enough that a clean workspace is the difference between a 100,000-mile engine and a 1,000-mile failure. Before you begin assembly, wash the new AS41 case and all internal components in a solvent tank or with high-quality brake cleaner to remove any residual machining oils or shipping preservatives. Even though these parts are new, tiny metal shavings can hide in oil galleries. Use compressed air to blow out every passage. Additionally, always "dry fit" your rotating assembly without sealant first to ensure that there is proper clearance for the rods and that the crankshaft spins freely. Double-checking your tolerances now prevents a catastrophic teardown later.

2. Master the Camshaft Break-In Procedure

The most critical thirty minutes of your engine''s life occur immediately after the first fire-up. To ensure the lifters and camshaft lobes seat correctly, you must use a high-zinc (ZDDP) assembly lube during the build and a specialized break-in oil for the initial run. Once the engine starts, do not let it idle. Immediately bring the RPMs up to between 2,000 and 2,500 and vary the speed slightly within that range for 20 to 30 minutes. This ensures that the splash lubrication from the crank provides enough oil to the cam lobes. Failing to follow this procedure can "wipe" a cam lobe, necessitating a full engine teardown to replace the cam and lifters.

3. Optimize Cooling and Fueling for Long-Term Health

The 1600cc Super Stock kit provides more power, which inherently generates more heat. To protect your investment, ensure that your engine tinware is complete and fits tightly; any gaps in the tin will allow hot air to recirculate into the cooling fan. I highly recommend using a genuine Dog-House style fan shroud and oil cooler setup to keep head temperatures in check. Furthermore, since this kit uses upgraded dual-port heads and a slightly more efficient valvetrain, ensure your carburetor is jetted correctly. Running too lean will cause the engine to run excessively hot, especially with modern ethanol-blended fuels. A slightly richer mixture will keep the combustion chambers cooler and extend the life of your valves and seats.