Engine Case, Aluminum, Stock Bore, for 8mm Studs

Overview

When it comes to building a foundation that lasts, the EMPI Aluminum Engine Case is the gold standard for air-cooled enthusiasts who are tired of dealing with the limitations of aging magnesium blocks. For decades, the VW community relied on AS-41 and AS-21 magnesium cases, which, while lightweight, are notorious for warping, "shuffling" at the main webs, and pulling head studs after years of heat cycles. This aluminum replacement case solves those issues by providing a significantly more rigid and durable platform. Engineered with extra material in key high-stress areas, this case offers the structural integrity needed to survive the rigors of modern driving. Whether you are performing a concourse-quality restoration on a vintage Beetle or assembling a rugged powerplant for a weekend sand rail, this aluminum case provides the peace of mind that your engine''s "backbone" won''t let you down when the temperature rises.

This specific iteration of the EMPI aluminum case is designed for a stock bore, making it the perfect direct replacement for 1500cc and 1600cc engines. It comes pre-equipped with 8mm case savers, ensuring that your head studs have a secure, steel-to-aluminum interface that resists stripping and pull-out. The dual-relief oiling system ensures consistent oil pressure management, which is vital for the longevity of your bearings and lifters. Furthermore, the universal design of this case means it is ready for Type 1, Type 2, and Type 3 configurations, featuring the necessary mounting bosses for various exhaust and cooling tin setups. By choosing aluminum, you are investing in an engine block that maintains its tolerances much better than magnesium ever could, ensuring that your line bore remains true and your internal clearances stay within spec for thousands of miles to come.

Fitment

This universal Type 1 engine case is designed to fit a wide array of air-cooled Volkswagen vehicles and custom applications. Please note that while it fits the following models, some specific tinware or mounting hardware adjustments may be required depending on your specific year and configuration:

• Volkswagen Beetle: 1950-1977 (Standard and Super Beetle)
• Volkswagen Karmann Ghia: 1956-1974
• Volkswagen Bus / Type 2: 1950-1971 (Upright 1600cc configurations)
• Volkswagen Type 3 (Squareback, Fastback, Notchback): 1962-1973
• Volkswagen Thing (Type 181): 1973-1974
• Custom Applications: Ideal for Dune Buggies, Sand Rails, Trikes, and Kit Cars using a Type 1 upright engine platform.

Technical Specifications

• Material: High-Strength Virgin Aluminum Alloy
• Bore Size: Stock (Designed for 85.5mm or 87mm Piston/Cylinder kits)
• Stud Size: 8mm (Includes pre-installed steel case savers)
• Oil Relief: Dual Relief (For superior oil pressure control)
• Oil Pickup: Includes Medium Diameter Oil Pickup Tube
• Configuration: Universal Type 1, 2, and 3
• Weight: Approximately 48 lbs (Provides superior rigidity over magnesium)
• Main Bearing Saddles: Machined to standard factory specifications
• Camshaft Compatibility: Fits standard and performance flat-tappet camshafts

Pro Tips from the Appletree Garage

Tip 1: Comprehensive Pre-Assembly Cleaning is Mandatory

Even though this is a brand-new component, you must never assume it is ready for assembly straight out of the box. During the manufacturing and machining process, tiny aluminum shavings and polishing compounds can become trapped deep within the oil galleries. Before you even think about installing a bearing, you should remove all gallery plugs (if possible) and scrub the internal passages with engine brushes and high-quality solvent. Follow this with a high-pressure air blast to ensure every passage is bone dry and free of debris. A clean case is the only way to ensure your new bearings don''t get scarred during the initial break-in period.

Tip 2: Verify Your Oil Pump and Gallery Clearances

Aluminum cases are cast thicker than original magnesium cases for added strength. While this is a major benefit, it occasionally creates tight clearances for certain aftermarket high-delivery oil pumps or deep sumps. Before applying any sealant to the case halves, do a "dry fit" of your oil pump. Ensure the pump slides in smoothly and that the drive tang engages the camshaft properly without binding. If you are using a performance camshaft with a high-lift lobe profile, also check for clearance between the lobes and the internal case webbing. It is much easier to do a little light clearancing now than it is after the case is sealed and torqued.

Tip 3: Manage Heat with Proper Tinware and Cooling

It is a common misconception that aluminum cases "run hotter" than magnesium. While aluminum does have different thermal properties, the reality is that the strength of the aluminum allows it to maintain its shape even when things get warm. However, because aluminum is denser, it can take longer to shed heat once it gets hot. To maximize the life of your new engine, ensure that all of your engine tinware is present, properly sealed, and that your thermostat system is functioning correctly. Using a high-quality external oil cooler in conjunction with the stock doghouse cooler is a great way to take full advantage of the durability of an aluminum case, especially in hotter climates or heavy-duty applications.