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Old 04-05-08, 02:08 PM   #1
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Default Banjo (Union) bolt removal/re-install

This is a step by step of how to remove the Banjo bolt that is on the engine block just across from the up-pipe top flange. Its the one with a filter screen that others have indicated should be cleaned or replaced periodically. Subaru calls it a "Union screw (with protrusion)."

Tools needed:
12 mm socket - for intercooler bracket bolt
14 mm deep-well socket - for up-pipe bracket nut and bolt
10 mm socket or wrench - for stock turbo heat shield bolt
17 mm wratcheting wrench - for Banjo bolt
10 inch or longer extension - to reach up-pipe bracket bolts

Parts needed (See pic "Union bolt and washer part numbers"):
Union screw (if replacing) - Subaru part # 14445AA090
Copper washers (2) - Subaru part # 803912040

Removal and re-install takes about one hour.


Start by removing any heat shields that are in the way. I have the SPT heat shield that comes off by removing the 12 mm intercooler support bolt.
(See pic "Engine bay area"). I also have the stock turbo heat shield installed. I didn't take it off, but there will be a little more room to work if you do. A 10 mm socket is needed to remove the stock heat shield bolts.

Next, the up-pipe bracket needs to be removed to be able to get a wrench onto the Union screw. Remove the nut (on the up-pipe stud) and the other bracket bolt (See pic "Up pipe bracket").

You can just barely see the Union screw from above once the up-pipe bracket is removed (See pic "View1 union bolt").

Next, remove the Union screw using the 17 mm wratcheting wrench (See pic "Wrench on union bolt"). I was only able to get about two clicks of travel on the wrench at a time. After a few turns I was able to get my fingers on the bolt to speed up the removal.

Once the old bolt is removed, you can try to replace the copper washer between the oil pipeline and the engine block with a new one. I was OK with leaving the old one there. I did use a new washer on the new bolt. You can clean up the screen in the old bolt and re-use it, I suppose. I felt better putting a new one in.

The torque spec on the Union screw is 21.4 ft-lbs (29 N-m). I could not get a torque wrench in there so I estimated the tightness based on the way it felt when loosening the old one. Be carefull not to overtighten! I ran the engine for a few minutes and checked for leaks before reinstalling the up-pipe bracket and heat shield.

Next, install the up-pipe bracket using the 14 mm deep-well socket and extension. The torque is 24.6 ft-lbs (33 N-m).

Re-install the stock heat shield using the 10 mm socket. I tightened them to "snug."

Finally, re-install anything else you needed to remove to access the Banjo bolt.

I plan to check for any oil leaking over the nexy few days.

I have about 30K miles on my 06 STi. I don't plan to do this again for at least another 30k miles, unless I have a problem as a result of the screen being clogged.

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Last edited by Mack; 11-05-08 at 11:20 AM. Reason: add attachments
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Old 04-07-08, 03:38 PM   #2
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Default Re: Banjo (Union) bolt removal/re-install

im gonna do this when i get my 20g!!
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Old 08-01-08, 09:56 AM   #3
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Default Re: Banjo (Union) bolt removal/re-install

Just curious but how dirty did your screen look when you did this?
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Old 08-01-08, 11:10 AM   #4
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Default Re: Banjo (Union) bolt removal/re-install

What indications would we get if our screen is clogged or dirty? Anything obvious? Or would this measure be more a preventative effort?
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Old 08-01-08, 11:26 AM   #5
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Default Re: Banjo (Union) bolt removal/re-install

Quote:
Originally Posted by STISubSilver View Post
What indications would we get if our screen is clogged or dirty? Anything obvious? Or would this measure be more a preventative effort?
^^^ a blown turbo,due to oil starvation.def preventative,many people remove it all together.so i have read
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Old 08-01-08, 12:06 PM   #6
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Default Re: Banjo (Union) bolt removal/re-install

I thought there were two banjo bolts with screens?
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Old 08-01-08, 02:28 PM   #7
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Default Re: Banjo (Union) bolt removal/re-install

Quote:
Originally Posted by skyline8409 View Post
I thought there were two banjo bolts with screens?
Yep. One for the active valve system and one for the turbo.
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Old 08-01-08, 04:10 PM   #8
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Default Re: Banjo (Union) bolt removal/re-install

Quote:
Originally Posted by skyline8409 View Post
I thought there were two banjo bolts with screens?
there are 3 of them - 2 for the AVCS and one in the turbo oil feed line.
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Old 08-04-08, 09:40 AM   #9
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Default Re: Banjo (Union) bolt removal/re-install

All three of them have screens?
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Old 08-04-08, 09:44 AM   #10
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Default Re: Banjo (Union) bolt removal/re-install

Quote:
Originally Posted by skyline8409 View Post
All three of them have screens?
only MY04 and the beginning of MY05 have AVCS screens. There was a Subaru TSB that recommended removing the AVCS filters.

Edit: good write up btw
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