Engine Case, Aluminum, 90.5 & 92mm Bore, for 8mm Studs

OVERVIEW

When you are building a high-performance air-cooled engine, the foundation is everything. The EMPI Aluminum Engine Case is the gold standard for builders who have moved beyond the limitations of aging, factory magnesium blocks. This case isn''t just a replacement; it is a significant structural upgrade designed to handle the stresses of increased displacement and high-torque stroker cranks. Crafted from high-quality aluminum and precision-engineered via CNC machining, this case offers superior dimensional stability and heat dissipation compared to original equipment. The "bubble top" raised roof design is a game-changer for engine builders, providing the necessary internal clearance for long-stroke crankshafts up to 86mm without the need for extensive and risky hand-grinding that can weaken the structural integrity of the main webbing.

Every detail of this case has been optimized for the modern VW enthusiast. It features a universal dual-bypass oiling system, making it compatible with a wide range of oiling configurations, and comes pre-drilled and tapped for a full-flow oil system right out of the box. Strength is prioritized where it matters most, specifically in the reinforced head stud areas and the filled-in section behind the number three cylindera notorious weak point in factory castings. To ensure the main bearings stay exactly where they belong under high RPM, the case is shuffle-pinned on all main saddles. Whether you are building a 1776cc daily driver or a 2276cc weekend warrior, this aluminum case provides the rigid, reliable platform required to protect your investment and ensure your engine lives a long, leak-free life.

FITMENT

This engine case is designed for Type 1, 2, and 3 air-cooled applications using 8mm cylinder studs. While it is a universal-style case, please note that the "bubble top" design requires minor modifications to the stock fan shroud. It fits the following models:

• Volkswagen Beetle: 1950 through 1979 (Sedan and Convertible)
• Volkswagen Super Beetle: 1971 through 1979
• Volkswagen Karmann Ghia: 1956 through 1974
• Volkswagen Bus / Type 2: 1950 through 1971 (Up to 1600cc configurations)
• Volkswagen Type 3 (Squareback, Fastback, Notchback): 1962 through 1973
• Volkswagen Thing (Type 181): 1973 through 1974
• Custom Applications: Ideal for Sand Rails, Dune Buggies, and Kit Cars using VW-based transaxles.

SPECS

Below are the technical specifications and features that set this aluminum case apart from standard magnesium replacements:

• Material: High-Quality Cast Aluminum Alloy for maximum strength and heat management.
• Bore Size: Pre-cut for 90.5mm and 92mm cylinder barrels.
• Stud Size: Machined for 8mm cylinder studs (Inserts included).
• Crankshaft Clearance: Bubble-top design clearanced for up to 86mm stroke crankshafts.
• Oiling System: Universal Dual-Bypass design for consistent oil pressure.
• Full Flow: Pre-drilled and tapped for full-flow oiling with a 1/4 inch NPT plug installed.
• Main Saddles: Shuffle-pinned on all main bearing saddles to prevent "walking" under load.
• Oil Gallery: Main oil gallery is tapped and plugged for easy cleaning and inspection.
• Cam Plug: Designed for a grooved-style cam plug for a superior seal.
• Reinforcements: Extra material behind the #3 cylinder and reinforced head stud bosses.
• Weight: Approximately 42 lbs (roughly 20 lbs heavier than magnesium for added rigidity).

PRO TIPS

Pro Tip 1: Thorough Cleaning is Mandatory. Even though this case is brand new and CNC machined, you must never assemble an engine directly out of the box. Manufacturing residues, fine metal shavings from the tapping process, or shipping dust can be trapped in the oil galleries. We recommend removing all gallery plugs, scrubbing the internals with hot soapy water and a specialized engine brush kit, and then blowing out every passage with high-pressure compressed air. This ensures that your brand-new bearings aren''t scored by debris on the very first startup.

Pro Tip 2: Fan Shroud Clearancing. Because this case features the "bubble top" raised roof to accommodate stroker cranks, it is slightly taller in the center than a stock magnesium case. When installing your 36HP or late-style fan shroud, you will likely encounter a small interference fit. Use a marker to identify the contact points on the bottom lips of the shroud and use a pair of tin snips or a small grinder to trim the tin for a perfect fit. Don''t force the shroud down, as this can lead to cooling leaks or vibration noise.

Pro Tip 3: Aluminum Case Thermal Expansion. Aluminum has a different rate of thermal expansion than magnesium. When installing your 8mm studs, we recommend using a high-quality thread locker and ensuring the studs are bottomed out correctly but not over-torqued into the block. Additionally, because aluminum cases expand more when hot, it is critical to double-check your deck height and valve train geometry. If you are used to building magnesium engines, you might find that you need slightly different shimming to maintain the desired compression ratio once the engine reaches operating temperature.