Re: P.O.S...

["Al Powell" <APOWELL@agcom.tamu.edu>]

> Jeez, Al, please calm down!

I have.  Large helpings of beer and lasagna for dinner, plus walking 
away, have helped.

> Having gone thru the same procedure (plus cam & lifter R&R), I can only
> note that these things generally take longer the first time, and are
> frustrating until you figure out the technique.

Agreed.
 
> I agree that that some of the things, at first blush,  don't make sense.
> (like the water pump).  But how many times have you seen "failed water
> pump on I5" on the list?  My I5 is running strong at 150K, using no oil
> between changes.  Is this a sign of poor design?

No, not in the pump itself.  As for how one ACCESSES the pump to 
replace it, you durn betcha.  Unnecessary complications.
 
> Did you remove everything in the way?  I was surprised how quickly the
> whole front end comes off the car, leaving easy access to the timing
> belt stuff.  

Left the bumper, etc. in place - but it really didn't make any 
difference relative to the timing belt.  Where it would have REALLY 
helped is in adjusting the alt. and AC belts...but I REFUSE to pull 
the front end off my car to adjust the %$*(^ belts.
 
> Make sure you carefully clean & prep the water pump mating surface on
> the block, and put a thin film of silicone grease on the O-ring & block.
> (Audi mechanic clued me in on this; noted a service bulletin, rust pits
> on old blocks can chew the O-ring when you rotate the pump on timing
> belt adjust.)

I gotcha there, good buddy.  Got into my scuba kit and helped myself 
to some hi-grade silicone grease for that O-0ring.  First, I scraped 
the surface carefully with a sharp chisel which I have found leaves a 
super, super clean surface.  I use it on heads, thermostat housings, 
etc.

> I can point to a number of more difficult & frustrating R&R procedures,
> and do not associate this with poor engineering. 

I'll use the ole shade-tree mechanic phrase:
"If this $*%*& thing is so good, howz come they can't make it easier 
to work on??"

I contend that one of the hallmarks of fine design is not only 
excellent function, but ease of access and repair.  In fairness to 
Audi, all front-wheel drive cars I have encountered SUCK in this 
respect.  I'll take a rear-driver anytime for easier service.  In 
front-drivers, there's just too darn much stuff in too little space.

I can cite TWO items on the 200 as superbly designed for service
access:

1)  The grille comes out with four screws and two clips.  Wonderful!

(1a - the whole grille/light/trim in front is easy to remove...)

2)  The intercooler can be removed (although you'd never know it from 
the Bentley, which is 100% NON-helpful in this regard) by taking both 
hoses loose, then removing ONE hex-head bolt which is next to the 
innermost corner of the radiator.  Then the intercooler lifts out 
easily.  Easy, and beautiful design!

Cheers to all..


*.......................................................*
Al Powell, Ph.D.                 Voice:  409/845-2807
107 Reed McDonald Bldg.          Fax:    409/862-1202
College Station, TX 77843      
Http://agcomwww.tamu.edu/agcom/satellit/alpage.htm
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