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 Post subject: HOW TO: AVCS Banjo Filter & OCV Solenoid Removal P0011 P0021
PostPosted: Thu May 14, 2015 1:30 pm 
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Vehicle: 99 WRX, SH9 XTP

Posts: 362
Location: Sydney
Hi All,

I spent a long time googling for a decent write up on how to do this but didn't find anything helpful.
With a bit of advice from Skyrex via PM I had a go at it last weekend.

What are we doing? Removing the 2 intake banjo bolts from a 2.5L 2009 Forester XTP (manual) to remove the plastic oil filters. Also removing Oil Control Valves (OCV's) also known as AVCS solenoids to test and inspect.

Why would we be doing this? My car is suffering from intermittent hesitation between 1000-2000rpm and eventually threw a CEL code P0011: INTAKE CAMSHAFT POSITION - TIMING OVER-ADVANCED OR SYSTEM PERFORMANCE (BANK 1). From doing some research on the net these 2 symptoms were often attributed to blocked filters in the AVCS banjo bolts or failing OCV's in the AVCS system.

FYI: Bank 1 is the right hand side of the engine on the 2.5L (Bank 1 relates to the side which the number 1 cylinder is on).
If you got a CEL code P0021 this is exactly the same as P0011 however it relates to the left hand side of the system (bank 2).

Time and difficulty: 3 hours, not overly difficult but the first time around it will take a bit of time to find what you're looking for and work out what tools you have that will actually fit.

Process for Right Hand Side

Step 1: Remove the intake shroud that leads into the airbox and the Short Fat Bit (SFB) running form your airbox.

Image

Step 2: Undo the bolt holding the coolant tank in place and gently lift the tank out of the way (leave hoses attached).

Image

Step 3: (If removing OCV continue reading, if only removing banjo bolts skip to Step 6)
Pull the pictured tube off the engine to give yourself clearance when removing the OCV.
If you're clumsy maybe place something over the hole so that nothing falls down there.

Image


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Last edited by twisties on Fri Jun 19, 2015 9:21 am, edited 1 time in total.
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 Post subject: Re: DIY / HOW TO - AVCS Banjo Filter and OCV Solenoid Removal
PostPosted: Thu May 14, 2015 1:37 pm 
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Vehicle: 99 WRX, SH9 XTP

Posts: 362
Location: Sydney
Step 4: Unplug the blue clip from the OCV and undo the 1 bolt on top of the OCV that's holding it in place. Now you just need to widdle and pry the OCV backwards (towards the firewall) and it should slide out. I just a screwdriver for leverage, be gentle.
It will slide most of the way out and then you'll have to rotate it about 90 degrees for it to come the whole way.

Step 5: Testing the OCV with a 9v battery and 2 wires. This is very simple. 1 wire on each battery terminal and touch them on the terminals of the OCV. If it moves about 5mm then it is working. As you can see I did this on my green work bench which the council provided.
I then cleaned this part with Subaru's Upper Engine Cleaner (UEC) before dipping it in fresh oil and re-installing. Others have used WD40 for cleaning. Mine seemed fine so it was probably unnecessary but I did it anyway.
Note - Even though both of my OCV's passed this test it is apparent that the drivers side is still failing intermittently hence I am replacing it. Details regarding ordering new parts will be in the notes at the end of this post.

Image

Step 6: Removing the RHS banjo bolt. This is tricky only because of the bracket that covers up the top of the banjo bolt. Some have suggested removing the bracket but the bolts are in very awkward locations and I gave up trying to get them out.
My method involved bending the bracket as much as I could with a pair of pliers and using a dremel to grind out a bit more room for a 17mm socket.
If you have a 17mm spanner it may fit and negate the need to modify the bracket however I only had sockets so this is what I did.
I marked the top of the banjo bolt so I new roughly how tight to do it back up.
I reused the 2 copper crush washers that were in there and so far it hasn't leaked, I just tightened it up a little more than what it was originally. See notes at the bottom for details regarding crush washers.

Image

Step 7: Inspect the banjo bolt for the plastic filter. If it is not in the banjo bolt it may have stayed behind in the void that the bolt came from so check in there too. If you're like me then the filter has already been removed and you just wasted about an hour trying to get to it.

Image

Step 8: Re-install banjo bolt tightening it to just beyond where it was originally to ensure a seal with your re-used crush washers (you tightarse).
Try and bend the bracket back in place, ensuring it's clear of anything it may rub on.
Put your OCV back in including the bolt to hold it there. Clip it in place (if you don't this will throw another code as I realised later that afternoon) and plug in that hose you pulled out of the engine.
Bolt the coolant tank back in place and ensure that the airways are clean before reinstalling the SFB.
RHS is complete.


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 Post subject: Re: DIY / HOW TO - AVCS Banjo Filter and OCV Solenoid Removal
PostPosted: Thu May 14, 2015 1:41 pm 
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Vehicle: 99 WRX, SH9 XTP

Posts: 362
Location: Sydney
Process for Left Hand Side

Step 1: Remove the battery.. you don't need a picture for that do you?

Step 2: Clean around the oil filler tube because you are about to remove that and you don't want anything falling down the hole.
Now undo the 3 bolts holding the filler tube in place (1 near the top and 2 at the bottom). Put this somewhere safe/clean and put something in the oil filler hole on the engine in case you drop something (I used a rubber glove).
While you're here undo the 1 bolt holding part of the air pump in place.

Image

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Step 3: Remove the plastic cover over the front of the air pump. There's 1 plastic screw on the front face of it that comes out easily and then 2 sets of clips that hold it in place. I broke 1 side trying to jimmy it off, hopefully you have better luck!

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 Post subject: Re: DIY / HOW TO - AVCS Banjo Filter and OCV Solenoid Removal
PostPosted: Thu May 14, 2015 1:46 pm 
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Vehicle: 99 WRX, SH9 XTP

Posts: 362
Location: Sydney
Step 4: Remove the 3 bolts holding the air pump in place. Now squeeze the hose clamp that holds the pump to the bit of plastic we undid in step 2 with a pair of pliers and pry them apart to create some room for yourself. There's also a big grey plug in this area but I couldn't get mine undone so I left it where it was.

Image

Step 5: Now you can see the banjo bolt and OCV, remove the tube on the engine closest to the OCV plug (same as the Step 4 for RHS). Undo the bolt holding the OCV in place and wiggle it free, same as RHS. Now test it just like in Step 5 for RHS.

Image

Step 6: Once again mark the location of the banjo bolt and remove. This time I didn't need to modify any brackets but the socket I used did have to sit on a slight angle. If you had a 17mm spanner it would probably make life easier. Following Step 6 for RHS check for the plastic filter. Once again mine was gone already.

Step 7: Put everything back together and hope that you haven't created any new problems while trying to conquer this.

For what it's worth this is what the banjo filter would look like if you had one:
Image

Notes:
- As mentioned testing the OCV with a 9v battery will only show if the part is 100% dead. In my case is operated normally however it still fails intermittently hence I am replacing it anyway.
- Refer to this thread for more information and for details regarding logging AVCS to determine if it is definitely failing (tactrix required)
http://forum.liberty.asn.au/viewtopic.php?f=18&t=20233&sid=bd68bb7b0c4440de9c28a61fa507a572
- OCV part number for 2009 Foz XT: 10921AA080 ($57.03US each (OEM) from Partsouq)
- Crush washer part number for 2009 Foz XT: 803912040 ($0.40US each (OEM) from Partsouq)


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 Post subject: Re: DIY / HOW TO - AVCS Banjo Filter and OCV Solenoid Removal
PostPosted: Thu May 21, 2015 8:33 am 
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Vehicle: 99 WRX, SH9 XTP

Posts: 362
Location: Sydney
Update: I got my OVC's in the mail from Partsouq in about a week. Put the RHS in after work yesterday because that is the one I suspected was failing and I didn't have time to do the passenger side. So far there's a 99% improvement. The major hesitation/stutter is gone. I can't tell if there's still a slight bit of hesitation or if I'm just being hyper-sensitive because I'm looking for it. Either way I'm going to change the passenger side on the weekend.
Something else to note, and I don't know if this is just a coincidence or what, but having driven it for 1 day since putting the new part in my average fuel consumption has gone from 10.4L/100k down to 9.0L/100km. Come to think of it, I used to get in the 9's and it went up into the mid 10's ever since I started noticing this problem about 2 months ago.

Good luck to anyone else who's chasing this problem!

Very late edit: There's also a lot of info about this on Liberty ASN, I thought I'd linked this thread earlier but apparently not:

http://forum.liberty.asn.au/viewtopic.php?f=18&t=20233


Last edited by twisties on Tue May 17, 2016 12:21 pm, edited 1 time in total.

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 Post subject: Re: DIY / HOW TO - AVCS Banjo Filter and OCV Solenoid Removal
PostPosted: Thu May 21, 2015 9:00 am 
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Vehicle: MY05 XT - Silver

Posts: 375
Location: Sydney
Great write up. :drinks:

_________________
MY05 Forester XT with MRT XA


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 Post subject: Re: DIY / HOW TO - AVCS Banjo Filter and OCV Solenoid Removal
PostPosted: Thu May 21, 2015 11:11 am 
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Vehicle: MY10 XTP & MY06 RColt

Posts: 562
Location: Newcastle, NSW
:ugeek: :thumbs: :ok:


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 Post subject: Re: HOW TO: AVCS Banjo Filter & OCV Solenoid Removal P0011 P0021
PostPosted: Thu Jan 14, 2016 5:33 pm 
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Vehicle: MY10 XTP

Posts: 6
Location: Sydney
Excellent write up and most helpful to solve my OCV problem.

i would just like to point out that the bolts you removed are the union bolts that do not or should not have filters. The filtered banjo bolts (or referenced by union bolt with filter) is lower down the engine following the oil line.
It is best referenced by one of the part breakdowns, such as Opposed Forces website.
Image

In this diagram it shows the bolt you removed is just the union bolt (no filter)
bolt labelled '4' 15194AA270 SCREW-UNION

and that the union bolt with a filter is in a different location (harder to get to).
bolt labelled '3' 14445AA090 UNION SCREW AND FILTER ASSEMBLY
This bolt has a protrusion on the end of the bolt, which can easily help to identify you have the correct bolt.

A good write up on this can be referenced:
http://www.subaruforester.org/vbulletin ... ndex2.html

Hopefully this helps someone.


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 Post subject: Re: HOW TO: AVCS Banjo Filter & OCV Solenoid Removal P0011 P0021
PostPosted: Sat Jan 16, 2016 9:55 pm 
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I Say: Up the bum no babies
Vehicle: Undead SH9

Posts: 2409
Location: Cairns, Queensland
Faaaaar out! I was definitely experiencing this. I wonder if this is what lead to the bearing going?

Great write up man

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Bram wrote:
And the only way for it to fit is with force and ripping flesh


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 Post subject: Re: HOW TO: AVCS Banjo Filter & OCV Solenoid Removal P0011 P0021
PostPosted: Mon Jan 18, 2016 8:40 pm 
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Vehicle: MY10 XTP & MY06 RColt

Posts: 562
Location: Newcastle, NSW
Holy mother of Kanye, that's a good pickup, and a beesh of a job to get at!
Was hoping it to be a quick check tonight before bed. But I don't think so now.


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