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Refrigerant Leak Check: Inspection

WARNING: This page is about a different car, the 2003 Subaru Outback, 2003 Subaru Legacy, and 2003 Subaru Baja. However, it is still accessible from the selected car via links, so may be relevant.
  1. Operate the A/C system for approx. 10 minutes, and confirm that the high-side pressure shows at least 690 kPa (7.03 kg/cm2 , 100 psi). Then stop the engine to start the leak test.
  2. Starting from the connection between the high-pressure tube and evaporator, check the system for leaks along the high-pressure side through the compressor. The following items must be checked thoroughly.
    • Connection between the tube and tube fitting
      Fig 1: Connecting Between Tube & Tube Fitting
      G02872697Courtesy of SUBARU OF AMERICA, INC.
    • Connection between 2 parts
      Fig 2: Connecting Between 2 Part
      G02872698Courtesy of SUBARU OF AMERICA, INC.
    • Connection between the tube and nut
      Fig 3: Connecting Between Tube & Nut
      G02872699Courtesy of SUBARU OF AMERICA, INC.
  3. Check the joint and seam between the pressure switch (dual switch) and receiver dryer.
  4. Check the connections between the condenser and tubes, and welded joints on the condenser.

    The leak tester may detect the oil on the condenser fins as a leak.

  5. Check the joint between the compressor and hoses.
  6. Check the machined area of compressor and other joints on the compressor.
  7. Check the thermal limiter (if equipped) on the compressor housing.
  8. Check the compressor shaft seal at the area near the center of compressor clutch pulley.

    Some shaft seals show a slight amount of leakage about 28 g (1.0 oz) per year. This is not a problem.

  9. Starting from the connection between the low-pressure tube and evaporator, check the system for leakage along the high-pressure side through the compressor. The following items must be checked thoroughly.
    • Connection between the tube and tube fitting
    • Connection between 2 parts
    • Connection between the tube and nut
    Fig 4: Checking System For Leakage Along High-Pressure Side Through Compressor
    G02872700Courtesy of SUBARU OF AMERICA, INC.
  10. Visually check the rubber area of the flexible hose for cracks.

    Check the entire length of the flexible hose, especially the connection with the metal hose end.

    CAUTION: Carefully check the external surface of hoses and tubes at approx. 25 mm (0.98 in) per second.
    Fig 5: Checking Rubber Area Of Flexible Hose For Cracks
    G02872701Courtesy of SUBARU OF AMERICA, INC.
  11. Disconnect the drain hose from the evaporator case, and check the hose end for at least 10 seconds.

    After the test is finished, reconnect the drain hose.

  12. Turn the ignition key to ON position, and run the blower at high speed for 1 minute. Stop the blower to check the ventilation grille on the instrument panel. While moving the tester closer to the grille, run the blower for 1 or 2 seconds, then stop it. Check the grille at that point for at least 10 seconds.
    Fig 6: Checking Ventilation Grille On Instrument Panel
    G02872702Courtesy of SUBARU OF AMERICA, INC.
  13. Check the valve in the service port.
  14. Visually check the rubber seal in the service port cap.
    Fig 7: Checking Rubber Seal In Service Port Cap
    G02872703Courtesy of SUBARU OF AMERICA, INC.
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