AC Leak Found Evaporator MY05 STi

fast_xr4 · 03-26-2012, 09:44 AM

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.

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indytruckboy · 03-26-2012, 11:13 AM

you should get a expansion valve right away.

fast_xr4 · 03-26-2012, 12:24 PM

Good call. $20 insurance policy against going back in there.

boredazhell20 · 06-30-2012, 07:25 PM

Any pointers for this job? I am going to have to do this next week.

Civ2Sub311 · 07-01-2013, 11:17 AM

Hey OP. I have to do this same thing to my 04 WRX...do you have any more info or details on getting to the evap core and removing/replacing it? Please??

Also, can you link me directly to the core and the expansion valve? Having a hard time finding the exact parts on RockAuto. Did you need any other parts along the way like small things e.g. gaskets, bolts, fittings, etc?

As far as you know is this the same exact job on my 04 Rex vs your 05 STI?

Thanks.

EDIT: I found this which covers the replacement of the expansion valve with pics.
http://www.clubwrx.net/forums/genera...ed-c-help.html

Hopefully there isn't much else to the evap core replacement, but if you have anything OP, let me know! Thanks.

fawcetteng · 08-20-2013, 10:50 AM

just did this last weekend on my 2004. Evaporator from advance autoparts online, delivered to the door in three days, was $98. this was probably the easiest dash surgery job I've ever done on a car - about 2 hours total.

I'm curious - i've recently taken my car on a couple gravel road trips, a few hundred miles total. the core is held in place by a tight fit in the plastic and foam, only bolted connection being the two aluminim lines. wonder if the bouncing caused a leak?

after removing the glove box i removed the fan, possibly differently from the OP as i just pulled it out with the aix box above it, two bolts and one nut up high under the dash. covering this nut was a plastic nut-like clip holding the wiring loom - see the white piece in the photo below. the nut you then remove is just behind it.

to remove the fan from under the dash i had to remove this relay bracket to get it out of the way- two nuts.

refer to the expansion valve link on the 7-1-2013 reply above for more photos of the next steps. there is a plastic cover where the fan fed to with a half dozen screws you need to remove - white plastic. look at how it covers the expansion valve at the firewall before removing. you have to get it back the same way.

after this you will see the lines going to the evap. expansion valve is the rectanular aluminum block you will see. as per the above link, remove the bolt then allen head screws from within the engine compartment to loosen the evap from the valve. there are o-rings on the tubes, both in the engine bay and on the evap lines, so be careful not to pinch them. the advance part did not come with new o-rings so you have to transfer them over from the old core.

TurBaja05 · 04-04-2014, 03:54 PM

sounds like this is the job i need to perform on my 05 baja turbo. have recently lost all cooling after hearing a light hissing noise coming from glove box area. recharged system, same hissing noise returned with a/c on, and after a couple weeks all cooling was lost again. hissing noise only occurs with a/c on so i know it is directly linked.

hope i can figure it all out without too much trouble.

03-26-2012, 09:44 AM	#1
fast_xr4 Scooby Newbie Member#: 73335 Join Date: Oct 2004 Chapter/Region: South East Location: Anderson, SC Vehicle: 2005 WRX STi	AC Leak Found Evaporator MY05 STi 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. * Registered users of the site do not see these ads.

07-01-2013, 11:17 AM	#5
Civ2Sub311 Scooby Specialist Member#: 178149 Join Date: Apr 2008 Chapter/Region: NESIC Location: CT Vehicle: 2018 WRX Limited CWP	Hey OP. I have to do this same thing to my 04 WRX...do you have any more info or details on getting to the evap core and removing/replacing it? Please?? Also, can you link me directly to the core and the expansion valve? Having a hard time finding the exact parts on RockAuto. Did you need any other parts along the way like small things e.g. gaskets, bolts, fittings, etc? As far as you know is this the same exact job on my 04 Rex vs your 05 STI? Thanks. EDIT: I found this which covers the replacement of the expansion valve with pics. http://www.clubwrx.net/forums/genera...ed-c-help.html Hopefully there isn't much else to the evap core replacement, but if you have anything OP, let me know! Thanks. Last edited by Civ2Sub311; 07-01-2013 at 01:50 PM.

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03-26-2012, 11:13 AM	#2
indytruckboy Scooby Specialist Member#: 192599 Join Date: Oct 2008 Chapter/Region: MAIC Location: Reading, PA Vehicle: 2004 STI 2007 Outback Wagon	you should get a expansion valve right away.

03-26-2012, 12:24 PM	#3
fast_xr4 Scooby Newbie Member#: 73335 Join Date: Oct 2004 Chapter/Region: South East Location: Anderson, SC Vehicle: 2005 WRX STi	Good call. $20 insurance policy against going back in there.

06-30-2012, 07:25 PM	#4
boredazhell20 Scooby Newbie Member#: 220880 Join Date: Aug 2009 Chapter/Region: SCIC Location: Southern Cali Vehicle: 2004 forester xt	Any pointers for this job? I am going to have to do this next week.

08-20-2013, 10:50 AM	#6
fawcetteng Scooby Newbie Member#: 340212 Join Date: Dec 2012 Location: Bryan, TX USA Vehicle: 2004 WRX Black	just did this last weekend on my 2004. Evaporator from advance autoparts online, delivered to the door in three days, was $98. this was probably the easiest dash surgery job I've ever done on a car - about 2 hours total. I'm curious - i've recently taken my car on a couple gravel road trips, a few hundred miles total. the core is held in place by a tight fit in the plastic and foam, only bolted connection being the two aluminim lines. wonder if the bouncing caused a leak? after removing the glove box i removed the fan, possibly differently from the OP as i just pulled it out with the aix box above it, two bolts and one nut up high under the dash. covering this nut was a plastic nut-like clip holding the wiring loom - see the white piece in the photo below. the nut you then remove is just behind it. to remove the fan from under the dash i had to remove this relay bracket to get it out of the way- two nuts. refer to the expansion valve link on the 7-1-2013 reply above for more photos of the next steps. there is a plastic cover where the fan fed to with a half dozen screws you need to remove - white plastic. look at how it covers the expansion valve at the firewall before removing. you have to get it back the same way. after this you will see the lines going to the evap. expansion valve is the rectanular aluminum block you will see. as per the above link, remove the bolt then allen head screws from within the engine compartment to loosen the evap from the valve. there are o-rings on the tubes, both in the engine bay and on the evap lines, so be careful not to pinch them. the advance part did not come with new o-rings so you have to transfer them over from the old core.

04-04-2014, 03:54 PM	#7
TurBaja05 Scooby Newbie Member#: 360425 Join Date: Jun 2013 Chapter/Region: TXIC Vehicle: 2005 baja turbo silver	sounds like this is the job i need to perform on my 05 baja turbo. have recently lost all cooling after hearing a light hissing noise coming from glove box area. recharged system, same hissing noise returned with a/c on, and after a couple weeks all cooling was lost again. hissing noise only occurs with a/c on so i know it is directly linked. hope i can figure it all out without too much trouble.