A Bug That Refuses To Fade
While Volkswagen is now known for crossovers like the Tiguan and Atlas – two of its best-selling models in the U.S. last year – the brand was once defined by a small, quirky vehicle that many people recognize: the Beetle.
The Beetle is one of the best-selling cars of all time, alongside the Ford Model T and Toyota Corolla, so it’s no surprise that it still holds relevance even after production ended in 2019. One of the more than 21 million units sold was this 1978 model, which was rebuilt after its engine failed nearly two decades ago.
Joy van Haelen on YouTube took on the job despite being on a tight budget. She also admitted to not being familiar with the engine, which was an air-cooled flat-four mounted at the rear – similar to the configuration used in the Porsche 911. Nevertheless, she viewed the project as a valuable learning experience for herself, rather than opting for an engine swap.
Getting Hands Dirty With A Classic
The bearings were initially believed to be part of the problem. Van Haelen sourced a new set for the engine, which helps rotating components such as the crankshaft and connecting rods operate smoothly by reducing friction. She also picked up a Haynes manual to provide a step-by-step guide for disassembling and reassembling the engine components.
However, the builder later discovered that the real issue was the connecting rods, which she said were no longer “perfectly round.” Discoloration on the components also suggested they had overheated, causing them to expand and damage surrounding parts. As a result, she sourced a new set of rods, which connect the pistons inside the cylinders to the crankshaft.
A Rebuild Full Of Surprises
Another issue emerged during the finishing touches. The new cylinder jugs that came with the pistons as part of a package deal were thicker, which meant they would not fit in the crankcase. Van Haelen had to remove them and reinstall the old ones. She admitted the setback was a bit discouraging, but understood it was part of the learning process.
Because the Volkswagen Beetle uses an air-cooled system, it is generally less complicated than water-cooled setups. It does not require additional components like a radiator or coolant system, making maintenance easier. In real-world conditions, however, the system is at higher risk of overheating.
It remains unclear whether the engine will run, as the reinstallation into the engine bay has not yet been shown. The builder also does not appear to have disclosed any long-term plans for the car, such as whether it will be sold. For reference, examples from this model year typically sell in the U.S. for around $15,000, with units in pristine condition commanding roughly double that figure.
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