ATTENTION:
GENERAL MANAGER

q

PARTS MANAGER

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CLAIMS PERSONNEL

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IMPORTANT - All
Service Personnel
Should Read and
Initial in the boxes
provided, right.

SERVICE MANAGER

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© 2025 Subaru of America, Inc. All rights reserved.

SERVICE INFORMATION BULLETIN
APPLICABILITY:
SUBJECT:

NUMBER:

All Models
New Procedure and Fail Code for First-Time
Undetected A/C Refrigerant Leaks

10-105-25R

DATE:

05/01/25

REVISED:

03/26/26

INTRODUCTION:
This Service Information bulletin announces the new procedure and Warranty Fail Code for FirstTime air conditioning (A/C) performance concerns possibly resulting from an undetected A/C
refrigerant leak. To improve Fixed Right First-Time (FRFT) and customer satisfaction, SOA is
introducing a new procedure and fail code for first-time suspected A/C refrigerant leaks for cases
when a Technician is unable to find the source of the leak or believes there was a potential factory
under charge of the A/C system refrigerant.
To ensure proper diagnostic procedures and prevent unnecessary Warranty claims, the current fail
code AVA: A/C Refrigerant Under/Over Charge will be replaced with CHR: AC Concern,
Technician Unable to Identify Root Cause.
Warranty Claim Submission Minimum Requirements:
1. Completed A/C Performance Check Worksheet(ALL PAGES)
2. Involvement of Techline and DSQM through normal escalation process
3. Submission of a Quality Monitoring Report (QMR) prior to repair order closure, including the
A/C performance check worksheet attached (this is a new worksheet)
WARNING: Failure to complete and provide any of the above warranty submission requirements
will result in claim rejection.
For any questions related to Warranty claims, contact the Claims team directly.
The information in this document is designed to help guide retailer staff through the
recommended diagnostic technique, appropriate fail code selection, and QMR requirements.

CAUTION: VEHICLE SERVICING PERFORMED BY UNTRAINED PERSONS COULD
RESULT IN SERIOUS INJURY TO THOSE PERSONS OR TO OTHERS.
Subaru Service Bulletins are intended for use by professional technicians ONLY. They
are written to inform those technicians of conditions that may occur in some vehicles,
or to provide information that could assist in the proper servicing of the vehicle. Properly
trained technicians have the equipment, tools, safety instructions, and know-how to
do the job correctly and safely. If a condition is described, DO NOT assume that this
Service Bulletin applies to your vehicle, or that your vehicle will have that condition.

Subaru of America, Inc. is
ISO 14001 Compliant
ISO 14001 is the international standard for
excellence in Environmental Management
Systems. Please recycle or dispose of
automotive products in a manner that is friendly
to our environment and in accordance with all
local, state and federal laws and regulations.

Continued...
Bulletin Number: 10-105-25R; Revised: 03/26/26

Page 1 of 8

TOOL REQUIREMENTS:
Subaru of America requires the use of Traceline dyes to assist in diagnosing refrigerant leak concerns.
Traceline TP3840 can be sourced from many local auto parts suppliers. Traceline TP9815 and the
required tools can be purchased at www.subaruretailersolutions.com.

SERVICE PROCEDURE & CLAIM PROCES FLOWCHART:
The following basic flow diagram is meant to support retailers with the proper diagnosis and
reporting requirements for AC performance related concerns.

Continued...
Bulletin Number: 10-105-25R; Revised: 03/26/26

Page 2 of 8

REFRIGERANT LEAK DETECTION PROCESS:
IMPORTANT: To ensure proper diagnosis, please refer to the SOA Techclips A/C Leak Check
Training video prior to performing the following steps. (MUST be logged into STAR-U to access)
WARNING: The Initial Setup & Performance Inspection steps 1 - 5 MUST be completed prior to any
evacuation or recharging of the AC system. If the pressures are within specification evacuation and
recharge are NOT necessary.
INITIAL SETUP & PERFORMANCE INSPECTION (PRIOR TO LEAK INSPECTION):
1. Connect AC manifold gauges and insert a thermometer in center vents.
2. Refer to the service manual procedure to inspect refrigerant pressures and performance: (Click
path) Heating & Air conditioner/Ventilator>Air Conditioner>Refrigerant Pressure with Manifold
Gauge Set à Procedure
Standard HVAC Settings for Performance Check
Item

Condition

Engine

Warming-up

Air vent grille

Full open

A/C switch

ON

Temperature setting

Lo (Max Cool)

FRESH/RECIRC position

RECIRC

Air flow control position

Vent

Fan speed

HI (MAX)

3. Conduct an AC performance test: The following characteristics indicate a potential refrigerant leak:
1. Pressures on both the high- and low side are low
2. Pressures on high- and low side are equal
3. High-pressure side is low
4. Low pressure side is low
4. Do not recover refrigerant immediately. If the characteristics are not one of the listed above, refer
to the service manual click path Heater & Air conditioner/Ventilation ˃ Air Conditioner ˃
Refrigerant Pressure with Manifold Gauge Set ˃ Inspection. There is no need to evacuate and
recharge for diagnosis.
5. If AC pressure characteristics are one of the four listed in Step 3, evacuate and recharge according
to the applicable service manual and proceed to the Refrigerant Leak Inspection Process below.
REFRIGERANT LEAK INSPECTION PROCESS:
STEP 1: Perform a visual inspection of the A/C components. Look for refrigerant oil stains and any
possible physical damage due to impact.

Continued...
Bulletin Number: 10-105-25R; Revised: 03/26/26

Page 3 of 8

STEP 2: Determine the type of dye necessary from the chart below.
Vehicle

12MY

13MY

14MY

15MY

16MY

17MY

18MY

19MY

Outback
& Legacy

20MY

21MY

22MY

23MY

24MY

25MY

26MY

TP-3840
TP-3840

Ascent
Crosstrek
& Impreza

TP-3840

TP-3840
TP-3840

BRZ

TP-3840

Forester

TP-3840
TP-3840

WRX
WRX STi

TP-9815

SHEV

TP-9815

Solterra
Crosstrek
Plug in
Hybrid

TP-9815

Step 3 – For vehicles requiring TP-3840 dye: Evacuate and vacuum the system for 30 minutes. For
vehicles requiring TP-3840, inject 3 grams of dye into the low-side service port, then recharge the
system according to the applicable service manual. Finally, run the vehicle with the A/C set to max.
for 30 minutes.
Step 3 – For vehicles requiring TP-9815 dye:
Evacuate and vacuum the system for 30 minutes. Recharge the system according to the applicable
service manual. With the A/C system not operating, unscrew the EZ-Ject dye handle completely and
screw the dye cartridge into it. Hold the cartridge vertically with the small cap on top. Remove the
cap and screw the cartridge firmly onto the coupler. Turn the handle to advance the plunger until
a small amount of dye exits the assembly. Remove the adapter/purge fitting—the coupler is now
purged. Connect the coupler to the low-side service port on the vehicle. Turn the plunger until 3
grams of dye are injected. Start the vehicle and run it for 30 minutes with the A/C set to max.
STEP 4: Using the UV light, check the following areas:
Under Hood
1.

Pipe-to-expansion valve connections (especially high-pressure side).

2.

Pressure sensor connection and T-fitting.

3. Welded joints along the liquid line to the condenser.
Condenser
4.

Pipe/condenser connection (bottom side).

5.

Low-pressure hose connection before the heat exchanger.

6. Welded sections and receiver/dryer.

Continued...
Bulletin Number: 10-105-25R; Revised: 03/26/26

Page 4 of 8

7.

Inspect condenser face for damage (rock chips).

Compressor & Hoses
8.

High-pressure hose-to-compressor and condenser connections.

9.

Flexible rubber hoses (watch for slow leaks).

10. Service port check.
11. Check compressor (note: shaft seals may allow minor acceptable leakage).
Low-Pressure Side
12. Expansion valve outlet.
13. Compressor low-pressure line & service port.
Evaporator & Interior Components
14. Rear evaporator lines and connections.
15. Evaporator drainage test after running the blower.
16. Inspect inside vents for refrigerant traces.
STEP 5 : Has the source of the leak been identified?
Yes: Perform the repair following the applicable Service Manual. If the vehicle is within 6
months of its production date, consider submitting a QMR to help support quality initiatives.
No: Proceed to Step 6.
STEP 6 : Escalate to Techline:
Has the source of the leak been identified after working to identify the leak with Techline?
Yes: Perform the repair following the applicable Service Manual. If the vehicle is within 6
months of its production date, consider submitting a QMR to help support quality initiatives.
No: Techline will proceed with the normal escalation process and escalate the case for
District Service & Quality Manager (DSQM) involvement.
STEP 7 : DSQM Technical Assistance:
Has the source of the leak been identified during DSQM technical assistance?
Yes: Perform the repair following the applicable Service Manual. If the vehicle is within 6
months of its production date, consider submitting a QMR to help support quality initiatives.
No: A Quality Monitoring Report (QMR) is required for any AC condition where the source
of the leak cannot be identified and Fail Code CHR is used prior to repair order closure. The
report MUST include the following:

Continued...
Bulletin Number: 10-105-25R; Revised: 03/26/26

Page 5 of 8

WARRANTY / CLAIM INFORMATION:
IMPORTANT: Claims for vehicles within the New Car Adjustment period, will require a Quality
Monitoring Report (QMR) prior to repair order closure, A Techline Case # and DSQM Technical
Assistance for any AC condition where a root cause cannot be identified and Fail Code CHR is used.
The report MUST include the following:
•

A completed A/C performance worksheet (accessed in the service procedure or at the end of
this document.

•

Customer complaint details (EXAMPLE: weak cooling, no cooling, poor A/C performance)
and duplication. Note: The customer concern must be duplicated to qualify for a CHR Claim.

•

Assistance through the normal escalation process with support from Techline and/or the
District Service & Quality Manager (DSQM).
Labor Description

Labor Operation #

Labor Time

Fail Code

AC CONCERN, UNABLE TO IDENTIFY ROOT
CAUSE

A704-101

1.7h

CHR-88

IMPORTANT: Effective June 1st, 2025 retailers MUST start the implementation of fail code CHR.
Fail Code AVA should no longer be used for first-time A/C refrigerant leak concerns where the root
cause cannot be identified. All claims’ submissions with a repair start date of June 1st or later are
subject to audit.

AC Performance Check Worksheet
IMPORTANT REMINDERS:
•

SOA strongly discourages the printing and/or local storage of service information as previously
released information and electronic publications may be updated at any time.

•

Always check for any open recalls or campaigns anytime a vehicle is in for servicing.

•

Always refer to STIS for the latest service information before performing any repairs.

Bulletin Number: 10-105-25R; Revised: 03/26/26

Page 6 of 8

AC Performance Check Worksheet (Complete both pages!)
Technician Name:
Date:
VIN:
Mileage:

Initial Checks & Setup
Confirmed CHR or AVA Fail Code has never been used. (One-time use)
Confirmed no history of AC Related Repair or Evacuation & Recharge
AC manifold gauges connected
Thermometer inserted in center vents

AC Performance Test Results:
Reference the appropriate service manual on STIS using click path: [Heater & Airconditioner/Ventilator -> Heater &
Airconditioner/Ventilator -> AIR CONDITIONER -> Refrigerant Pressure with Manifold Gauge Set -> PROCEDURE] for
specifications.
Vent Temperature:

°F (Target <50°F)

Ambient Temperature:

°F

High-Side Pressure:

PSI

Low-Side Pressure:

PSI

Customer Concern Duplicated?: Yes No (If No, STOP here! CHR should only be claimed when AC performance is
not within specification. Please use No Problem Found)
Refrigerant Amount Recovered:
Specification:

Grams

Grams

kg

kg

Step-by-Step Leak Detection
Visual Inspection:
No visible oil stains, rock chips, or damage on any components
Signs of potential leak (describe below)
AC Dye Inspection Preparation:
System fully charged & Dye installed
Run vehicle for 30 minutes in well ventilated area
Shut off engine and inspect AC system for leaks using UV light.

Continue to next page

Leak Detection Sequence:
Under Hood:
Pipe-to-expansion valve connections - No leak / Leak detected
Condenser:
Pipe/condenser connection - No leak / Leak detected/ No Impact Marks on Fins
Compressor & Hoses:
High-pressure hose-to-compressor connections - No leak / Leak detected
Low-Pressure Side:
Expansion valve outlet - No leak / Leak detected
Evaporator & Interior Components:
Rear evaporator lines & connections - No leak / Leak detected
Leak Identified?

Yes

No

If No, Techline escalation is required.
Summary & Findings
Contacted Techline?
DSQM Contacted?
Leak Found?

Yes Techline Case #:
Yes

Yes

No

No(see note below)

By selecting No to this question, you are agreeing that all proper diagnostic and escalation steps have been
taken prior to QMR submission. The use of fail code CHR: AC Concern, Technician Unable to Identify Root Cause
is now permitted. Should a vehicle return with a leak within 6 months of the claim, the CHR: AC Concern, Technician Unable to Identify Root Cause claim will be debited.
QMR Submitted?

Yes

QMR #:
Location of Leak(s):

Repair Actions Taken:

No