Refrigerant Leak Check: Inspection

WARNING: This page is about a different car, the 2003 Subaru Forester. However, it is still accessible from the selected car via links, so may be relevant.

Operate the A/C system for approx. 10 minutes, and confirm that the high-pressure side shows at least 690 kPa (7.03 kg/cm² , 100 psi). Then stop the engine to start the leak test.
Starting from the connection between the high-pressure pipe and evaporator, check the system for leaks along the high-pressure side through the compressor. The following items must be checked thoroughly.
Check the joint and seam between the pressure switch (triple pressure switch) and high-pressure pipe.
Check the connections between the condenser and pipes, and welded joints on the condenser. The leak tester may detect the oil on the condenser fins as a leak.
Check the joint between the compressor and hoses.
Check the machined area of compressor and other joints on the compressor.
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.
Starting from the connection between the low-pressure pipe and evaporator, check the system for leakage along the low-pressure side through the compressor. The following items must be checked thoroughly.
- Connection between two parts
- Connection between the pipe and plate
  
  Fig 1: Checking System For Leakage Along Low-Pressure Side
  Courtesy of SUBARU OF AMERICA, INC.
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 2: Checking Rubber Area Of Flexible Hose
Courtesy of SUBARU OF AMERICA, INC.
Disconnect the drain hose from the heater case, and check the hose end for at least 10 seconds.
After the test is finished, reconnect the drain hose.
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 3: Checking Ventilation Grille
Courtesy of SUBARU OF AMERICA, INC.
Check the valve in the service port.
Visually check the rubber seal in the service port cap.

Fig 4: Checking Rubber Seal In Service Port Cap
Courtesy of SUBARU OF AMERICA, INC.