When rebuilding an engine, or starting from scratch from a new case, there are a variety of additional items that need to be acquired to complete the assembly. There are a few critical kits out there from a few different manufacturers.
Type 1 Gasket Kit
The Type 1 Engine gasket kit is necessary to get to assemble the a Short Block, as well as a Long Block. There are a few additional gaskets and seals for additional stages of engine building.
A Type 1 kit typically contains the following:
- Dual Port Cylinder to Intake Manifold Gaskets (x 2)
- Exhaust Gaskets (x 4)
- Pre Heater to Manifold Gaskets (x 2)
- Oil Pressure Relief and Valve Washers (x 2)
- Alternator/Generator Oil Baffle Gasket (x 1)
- Dual Port Cylinder to Intake Manifold Gaskets (x 2)
- Type 3 Pulley/Fan Gasket (x 1)
- A Packet of paper gaskets
- Valve Cover gaskets (x 2)
- Oil Change Gasket and Washers (1 set)
- 1200cc rocker arm seals (x 4)
- Various oil cooler seals (x 6)
- 1300-1600 Rocker Arm O-Rings (x 4)
- Distributor O-Ring (x 1`)
- Main Case Bolt Internal O-Rings (x 6)
- Pushrod Tube Seals (x 16)
- 1300-1600 Flywheel O-Ring (x 1)
- There are some parts of the kit I have no idea what they are or what they may go to (marked by ?)
There are at least 3 kits on the market. I’ve decided on sticking with the German Elring Brand, but there are kits from Brazil as well as SCAT available.
Within the kit is also a collection of paper gaskets.
A Type 1 kit typically contains the following:
- 6mm Oil Pump Gaskets
- 8mm Oil Pump Gaskets
- Fuel Pump Flange gaskets
- Type 3 to Type 1 Block Off Gaskets
- Type 3 Pulley/Fan Gasket
- 55 and earlier Flywheel Gasket
- Cylinder Bore to Case Gaskets
- Alternator/Generator Stand Gaskets
- Oil Pump Bolt Gaskets (apparently can be used for bolts at #4 main and #1 cam bearing)
These kits all generalized and universal kits, so there’s quite a few seals, gaskets, etc. that are never going to be used on an original VW Type 1 engine.
Many new parts such as oil pumps, fuel pumps, etc. seem to all come with their own gaskets, some of which appear to be of better quality. This is especially true of the gaskets for the cylinder to manifold gaskets.
It is rare to find a kit that includes the main crankshaft oil seal. Some will be sold as a bundle, but the kits themselves don’t typically have this oh so crucial seal.
Type 1 Deluxe Nut and Washer Kit (8mm or 10mm depending on your cylinder studs)
As far as I’ve been able to tell, pretty much all these kits are made by EMPI. There may be some others out there, but every one I’ve purchased, regardless of vendor or marketing info, all show up on EMPI packaging.
The deluxe kits contain the additional extra bolts for a new Universal Type 1 engine. The basic kits do not. Both types come in either 8mm or 10mm varieties, depending on the size of a case’s cylinder studs.
A Deluxe Type 1 kit typically contains the following:
- 6 main case bolt locking nuts and washers
- 16 cylinder stud nuts and thick washers (8mm or 10mm depending on the kit)
- 2 case bolts (shorter) with nuts and washers
- 1 case bolt (longer) with nut and washer
- 8 exhaust nuts
- 6 acorn oil drain plate nuts
- 18 case locking nuts and washers
Now I’ve never used the exhaust nuts in these kits. I’ve read they are total shit and not really bronze and won’t last long. I’ve always used specific bronze nuts I’ve purchased, or those that come in the various exhaust assembly kits.
While some of the nuts and washers could probably be reused in an emergency situation, the main items in this kit are under both specific torquing and of course, exposed to the varying extreme temperatures of the engine block and cylinder heads. I cannot imagine the nylock locking nuts lasting long on reuse, especially if the engine has been run hard.
Type 1 Universal Case Hardware Kit
The Type 1 Universal Case Hardware Kit is also a necessity when starting out with a brand new AS41 universal case, as several key parts are needed.
These kits contain the following:
- An entire Dual Pressure / Oil Valve setup including the 2 springs, the 2 valves, 2 plugs, and 2 crush washers.
- The Type 3 to Type 1 dipstick block off cover including gasket, 2 studs , and 2 nuts
- 4 oil pump studs
- 2 case to transaxle studs
- 1 oil sump drain plate replacement stud
Now the one thing that I’ve seen all over the place, depending on the manufacturer and vendor, is the quality of the oil pressure relief valve bore plugs. The original VW ones were large flat head slotted and extremely difficult to remove on some engines. The AH engine disassembly of mine took hours to finally get them out. Some replacement case hardware kits come with hex plugs made for use with allen wrenches or socket attachments. These are much easier to install and remove and I would throw away any flat head ones I have (unless you are going to keep the engine 100% OEM stock setup.