AC Leak Found Evaporator MY05 STi

[fast_xr4]

I have a 2005 STi. The AC stopped blowing cold years ago. Around 75k miles I believe. I have been recharging my AC myself each season but it typically won't last more than a week. I added the dye several times in one season and never found a leak in the engine bay. Last season I could smell the refrigerant in the morning when I started the car and turned on the blower. Side note: According to the material safety data sheet, the R134a refrigerant is not harmful unless you are in an enclosed space and displace enough air to deprive you of oxygen.

I figured it had to be the evaporator or the connection to it. I finally tore into the dash after reading a few posts about it being possible to get to the evaporator without removing the upper dash.

I had previously replaced the cabin filter so I knew partially what I was getting into. This time I removed the glove box as done for a cabin filter change (10 or so Philips screws) and also the blower motor assembly (two 10mm bolts and several more Philips screws), several electrical connections and a few electronic controllers.

I was able to get to the evaporator and found the leak. I think this took about 2 hours without instructions of any kind including removal of the AC connections at the firewall. Keep in mind I am waiting for the replacement part (RockAuto $85 shipped vs $200+ for Subaru).







I hadn't read anything real definitive about doing this on an Impreza MY05 so I hope this is helpful to someone.