Replacement Sand Seal, Bolt In Style, Fits EMPI Brand

OVERVIEW

Protecting your air-cooled investment requires more than just regular oil changes; it requires a proactive defense against the harsh elements of the off-road world. The stock Volkswagen engine design utilizes a reverse-thread oil slinger on the crank pulley to keep lubrication inside the case, which works perfectly for standard street use. However, when you take your Beetle, Baja, or Sand Rail into the dunes, that same design can actually draw fine particles of sand and grit into your engine''s internals. This EMPI Replacement Sand Seal is the specialized solution for engines equipped with a bolt-in style sand seal kit. Designed specifically to replace worn or dry-rotted seals in EMPI brand assemblies, this component ensures that your crankshaft remains shielded from abrasive debris that can cause premature bearing failure and catastrophic engine damage.

This high-quality replacement seal is engineered for cases that have already been machined to accept a sand seal, providing a precise fit that prevents oil leaks while maintaining a vacuum-like barrier against the environment. Because this is a high-wear item in extreme conditions, keeping a spare in your trail box is a veteran move for any off-road enthusiast. It is important to note that this seal must be used in conjunction with an EMPI-style sand seal pulley to ensure the snout diameter matches the seal''s inner dimensions perfectly. Whether you are refreshing a long-running desert racer or finishing a new high-performance build, this bolt-in style replacement seal offers the durability and reliability that Appletree Auto customers have come to expect for their air-cooled Volkswagen powerplants.

FITMENT

This replacement sand seal is designed for air-cooled Type 1, Type 2, and Type 3 engines that have been machined for a bolt-in sand seal kit. It is compatible with the following models and applications:

• Volkswagen Beetle: All years and models with machined cases.
• Volkswagen Karmann Ghia: All years and models with machined cases.
• Volkswagen Bus / Transporter: 1950-1971 (Type 1 upright engines).
• Volkswagen Thing (Type 181): All years.
• Dune Buggies & Sand Rails: All custom builds utilizing 1200cc, 1300cc, 1500cc, and 1600cc based engines.
• Baja Bugs: Specifically those running EMPI brand bolt-in sand seal kits.
• Compatibility Note: Must be used with an EMPI brand sand seal pulley.

SPECS

Engineered to meet the exact tolerances required for high-RPM air-cooled engines, the technical specifications include:

• Inside Diameter (ID): 1.725 inches.
• Outside Diameter (OD): 2.260 inches.
• Material: High-temp synthetic nitrile rubber with a steel reinforcement housing.
• Style: Bolt-in / Press-in replacement for EMPI 00-8694-0.
• Kit Inclusions: Includes one (1) replacement seal.
• Application: Designed for machined cases (not for use with stock, un-cut cases).
• Resistance: High resistance to oil, heat, and abrasive sand.

PRO TIPS

1. Inspect Your Pulley Snout Before Installation

Before pressing in your new seal, it is absolutely critical to inspect the surface of your EMPI pulley snout where the seal makes contact. If there is a "groove" worn into the metal from the old seal, the new seal will likely leak almost immediately. If you feel a physical indentation with your fingernail, you should either replace the pulley or use a "speedi-sleeve" to restore the surface. A smooth, polished surface is the only way to ensure the new nitrile lip creates a proper, long-lasting seal against the elements.

2. Use Proper Lubrication During Assembly

Never install a sand seal dry. If the seal lip is dry during the initial startup, the friction against the pulley snout will generate immense heat within seconds, potentially melting or tearing the rubber lip before the engine oil has a chance to reach it. Apply a light film of clean engine oil or a high-quality assembly grease to both the inner lip of the seal and the outer diameter of the pulley snout. This ensures a smooth "break-in" period and prevents the seal from "chattering" or failing prematurely during its first few heat cycles.

3. Ensure Square Seating in the Case

When installing the replacement seal into the bolt-in collar or the machined case, you must ensure it is seated perfectly square. If the seal is cocked at even a slight angle, it will put uneven pressure on the pulley snout, leading to an oil leak and uneven wear. We recommend using a seal driver tool or a large socket that matches the outer diameter of the seal to tap it gently and evenly into place. Double-check that the seal is flush all the way around before sliding the pulley into position and torquing the gland nut.