Trusted Member
Posted 22 November 2014 - 03:34 PM
Cheers Adam. 
Good news on the AVCS front, it is now functioning as it should. So i just need to retune and i'll get to see what she's really got! (made 177.9 kW @ 14psi on run-in tune) It's running a bit rough at the moment as the run-in tune was not set up for the AVCS being active, so it has flat spots, hesitations and it splutters a bit at certain revs / certain load.
some more pieces of the puzzle
LPM_FOZ
Posted 22 November 2014 - 05:19 PM
This will be epic with all the bits working as they should, keen to see some hill climb videos with it at full tick 
Trusted Member
Posted 18 December 2014 - 04:52 PM
Bit of an update... AVCS was working intermittently, the mechanic has been troubleshooting for the last two weeks. Does not seem to be cam sensors, OCVs, banjo filters, solenoids or anything else in the AVCS system. The issue is only with the passenger bank inlet cam - not that the exhaust cams are readable electronically anyways... The mechanic believes it's the Cosworth cams. Either the grind is out in relation to TDC or the pinning is out. If you put the cam out by one tooth in the timing (retarded) the AVCS settles and remains stable, but she pings like a junkie.
So... timing has been returned to factory specs and the run-in tune has been re-flashed, I am significantly poorer and it's engine out for the early new year!
Not feeling the love at the moment.
LPM_FOZ
Posted 19 December 2014 - 12:05 AM
Been following your build on ozfoz
All i can say is you have had the worst luck
Hopefully the cams are sorted out with some compensation from cosworth
Trusted Member
Posted 13 January 2015 - 09:59 AM
Trusted Member
Posted 29 January 2015 - 03:08 PM
Cam was analysed and found to be only 0.2mm out from OEM. This is within tolerances...
this leaves three possible faults:
1. Cam position sensors
2. OCV solenoids
3. Cam gears
so....
Member's Member
Posted 30 January 2015 - 11:38 AM
Forken hell, such a dicking around you having to do.
Hope it improves.
Trusted Member
Posted 03 February 2015 - 09:43 PM
Forken hell, such a dicking around you having to do.
Hope it improves.
yeah bro it has not been ideal. I just want to be able to tune it properly 
I could have fitted the six speed, diff and upgraded the turbo with these unexpected expenses... i'll tell you what though - it's really good to be part of a community. I managed to round up those parts from a few different forums within days. The price from Subaru for the parts was in excess of $1500, i got these for under $600.
Touring Bruce
Posted 03 February 2015 - 09:51 PM
Im sure AVCS is great when its working but all this forking around is why ill be sticking with a pre AVCS engine for my conversion. Hope it goes well for you though
Trusted Member
Posted 10 February 2015 - 12:40 PM
the good:
Just got the phone call i've been waiting for. AVCS issue has been resolved very facking happy. I might be able to pick it up this week, but they can't dyno until next week - even though.... I'm still F@CKING HAPPY
the bad (but kind of secretly good):
the mechanic also said the clutch needed to be done as it was quite warn! I said, just put it back together, I have the six speed at home. So the Competition Clutch stage 2 clutch and flywheel have lasted about 10,000 kms and 1000 of that was bedding the clutch in, 5000 of that was running in the new engine and avcs issues. That's only 4000kms on boost - very disappointed in that.
So next job is fitting up the 09 DCCD six speed and R180 diff.
LPM_FOZ
Posted 10 February 2015 - 01:17 PM
skids ahoy
Trusted Member
Posted 16 February 2015 - 12:11 PM
So, all went well at last!
The mechanic believes it was the cam gears at fault - hard to be sure though as we swapped all components of the AVCS system.
180kW @ 16psi hits 2800rpm
Nice safe solid stable tune!
I'm going to run the current tune for a couple of thousand kms and ensure everything is running as it should before winding up the boost / timing etc...
A couple of issues encountered:
Turbo to AVCS 'hard' oil line failed at a soldered joint so it was replaced with a braided line and fittings.
Rear Passenger endlink snapped - love whiteline
Cobb EBCS is playing up and needs replacing - Only seen 10,000kms!
Also, in order to re-claim some of my shed i have created a 'to do' list:
Touring Bruce
Posted 16 February 2015 - 12:24 PM
This is going to be a weapon. Fingers crossed its done for HVC
LPM_FOZ
Posted 16 February 2015 - 01:08 PM
This is going to be a weapon. Fingers crossed its done for HVC
Plus juan
Would be awesome to see it
LPM_FOZ
Posted 16 February 2015 - 01:11 PM
So, all went well at last!
The mechanic believes it was the cam gears at fault - hard to be sure though as we swapped all components of the AVCS system.
180kW @ 16psi hits 2800rpm
Nice safe solid stable tune!
I'm going to run the current tune for a couple of thousand kms and ensure everything is running as it should before winding up the boost / timing etc...
A couple of issues encountered:
Turbo to AVCS 'hard' oil line failed at a soldered joint so it was replaced with a braided line and fittings.
Rear Passenger endlink snapped - love whiteline
Cobb EBCS is playing up and needs replacing - Only seen 10,000kms!
Also, in order to re-claim some of my shed i have created a 'to do' list:
To Do... in no particular order- 09 DCCD Six speed- DCCD Pro- 07 Spec-C 2-way R180- Rear Brembos and Rotors- Dual Catch Cans- New EBCS- Fuel pressure regulator- Finish Gauges- STi front strut brace- 24mm Front anti-sway bar- WRX Cluster swap- TMIC water sprayer- Black steering wheel controls- Project Mu wheel nuts- Hyperflow engine cover- Roof rail delete- eyelids- carnards- Black out roof lining and interior componentsshould keep me busy
Would swapping an sti cluster in be better over the wrx so you can mate it up with your DCCD box or will the DCCD Pro be used for that side of things?
Member's Member
Posted 16 February 2015 - 04:53 PM
Interested to see the WRX cluster when it's in. You bought one yet? I've got the same boring one as you.
Trusted Member
Posted 16 February 2015 - 04:54 PM
Would swapping an sti cluster in be better over the wrx so you can mate it up with your DCCD box or will the DCCD Pro be used for that side of things?
I had the wrx cluster from before deciding to go six speed, so it's kinda free 
The DCCD pro is not compatible with the 08+ STi cluster DCCD display either (crazy i know!). Dixon001 on ozfoz and i bought the DCCD pro together for a discount and saving on shipping. He is a sparky so he is making up a custom LED display that we can both use, i have the pre 08 toggle wheel controller for the centre console.
I am trying to keep the conversion to the tried and tested... I've had enough of things going pear shaped!
Trusted Member
Posted 16 February 2015 - 04:56 PM
Interested to see the WRX cluster when it's in. You bought one yet? I've got the same boring one as you.
Yeah got one already with about the same kms on the clock. The swap is plug and play with re-coding done by subaru - i also have the wrx transponders for the keys, but i think subaru still need to code the body module... i'll let you know!
New Member
Posted 16 February 2015 - 05:12 PM
Awesome bulid....I had AVCS issues as well in my build 1...and it continued in semi build 2 and into final build 3....
Build 1: Previous workshop hacked my AVCS cam gears and really....found out later they HACKED my build 1 completly.....dodgy as! ( HP...........F)
Build semi 2: New workshop...Build 1 was fixed but AVCS problem continued intermittenly but then lifted my head with E85 ( used oem studs in build 1)
Build 3: Continued with workshop and did a full build from the start...AVCS returned on run in tune.....Replaced everything like you did, intake cams gears, cam sensors, checked timing, checked voltages, cleaned out old OCV solenoids, checked cams.. etc etc and in the end was the OCV solenoids...
Sometimes it would be best to sacrifice AVCS all together and go old skool.....there's nothing wrong with no AVCS........oh well...maybe next time... 
As with all these types of builds....$$$$$, patience, and determination with a good workshop...and by going by the photos....its the same workshop I used and still use....and my engine is still going strong til this day....
Also help from Mr. Phil Lowe also helps heaps....
Goodluck and all the best....
Justin
~JUSZTN~
** Our Turbo Lag Gives Those v8's A Chance **
Past - MY07 Liberty TBSTI 6SPD Sedan
265kw atw on P100
290kw atw on E85(fuel pump limited)
Past - MY16 Audi S3 Sedan
Present - MY18 Audi RS3 Sedan (His)
Present - MY17 VW Tiguan 162 R line (Hers)
LPM_FOZ
Posted 16 February 2015 - 07:24 PM
I had the wrx cluster from before deciding to go six speed, so it's kinda free
The DCCD pro is not compatible with the 08+ STi cluster DCCD display either (crazy i know!). Dixon001 on ozfoz and i bought the DCCD pro together for a discount and saving on shipping. He is a sparky so he is making up a custom LED display that we can both use, i have the pre 08 toggle wheel controller for the centre console.
I am trying to keep the conversion to the tried and tested... I've had enough of things going pear shaped!
ah thats sweet then and yes id probably have necked myself with the amount of bad luck you have had, glad its looking up now
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