The VW internal oil cooler to an external oil cooler and generator to alternator conversion

BUY THE COMPLETE EMPI KITS. It will save you headaches in the long run. Converting from an internal oil cooler to an aftermarket oil cooler is easy on BAJA bugs. SO is the generator to alternator conversion... Stock VW's are a little harder because of the hood and shrouds.

Below are the pics of hows to's and what you will encounter

Above is the stock internal oil cooler seen with the shroud removed.... Below the stock internal cooler is removed. I used the old seals Only because the seal kit did not contain the seals for the smaller oil gallery. Thats OK... They were still reusable........ There are 2 types of seals. They depend upon what size your engine block has. I used the old ones because my engine had the smaller type seals on the block, large on the cooler or adapter. The cooler adapter most always has the larger step type seal. Small to big or big to big. Use a little Silicone Sealant to complete the seal....

Use a little wd40 for ease of installing the oil cooler lines onto the barbed fittings

Below is the Alternator and old generator. KEYWAYS must be installed and spacers, etc. must be observed/used for clearances (not to critical).. I used a chrome pulley and bought extra spacers just in case. A 1.5 inch socket fits perfectly to the cooler fan nut. MAKE SURE YOU BUY A NEW 12 volt INTERNALY REGULATED BOSCH ALTERNATOR(EMPI) as there are UNREGULATED Alternators that won't work properly with out an external regulator. The BOSCH INTERNAL REGULATED ALTERNATOR has 2 terminals and no more. Positive (B+) and the spade connector for the dash light (battery and IDIOT light are the only connections!) You'll also need an ALTERNATOR MOUNT(again EMPI). I also used a chrome fan shroud mounding plate.... CHROME, CHROME, CHROME, Looks cool!!!!

The throttle cable and fan shroud sleeve are the hardest part of the conversion only because we are using CHROME goodies(You'll have to drill holes) Insert the cable/guide into the holes you drilled for the throttle cable/guide. I used a hose clamp to secure the guide to the shrould. We also used a chrome shroud(hole for throttle guide must be drilled) and cylinder shrouds for the final conversion along with chrome screws(all EMPI again), etc.......

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