Have a look at this video.

See how badly the condenser is damaged but not leaking gas! Hum, could there be a design issue with the condenser that is being blamed as stone damage??

 

BTW, to clarify, by gas I mean refrigerant gas...

 

This thread may be of interest:

Toyota Nation - Inverter Radiator Damage

 

I ordered the black aluminum screen today to put behind the upper and lower grills of the 2022 to protect the condenser.

You will want one which is at least 41 by 16" so you can cut a 10" piece for the upper grill and 6" for below the bumper.
The 4 x 8mm mentioned in the other post seams to be a reasonable size opening.
I will use black zip ties to hold it in place. I do not believe the zip ties will be visible from the front.

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This is an excellent idea and I just did it to my corolla and Xb mk2 all from the same piece. It cuts well with tin snips, just beware of the sharp bits cutting creates.
There is enough left over that I may be able to use it on my sons XB mk1

 

Well, I pulled the top plastic cover and had a good look at the condenser. Could not see any damage. I took it to a recommended shop and they put the gauge on the AC and determined there was NO refrigerant (R1234) left in the system! They fully vacuumed the system and filled the system. I did not realise it takes approx. 31 ounces and at $12 and ounce, this was nearly $360 just for the referegerant. They also added dye. Based on initial inspections using a UV light, there was NO visible leaks from the condenser. I have to go back in 2 days for them to do another full inspection. However, initial indications is that Toyota was giving me a BS line about a damaged condenser and gouging me $1500 for a condenser repair (and I'm pretty sure, they would have charged me an addition $300-400 for the R1234).

BTW, can anyone confirm the capacity of the Highlander AC system ie. is it approx. 31-32 ounces?

 

AC refrigerant type and quantity should be printed on a sticker near the hood latch at the front of the engine bay. I don't know if gas and hybrid models have identical systems but on my hybrid it reads "900 +/- 30g". Off the top of my head, 900g should be just about 32 ounces.

It seems to me that if your system had no refrigerant left you definitely have a problem, they just haven't found it yet. It's a bit galling that they asked you to pay for a bunch of parts replacements without actually identifying the cause of the problem. Good idea trying someplace else to work on it.

 

Thanks for the information. The Service Center I went to was pretty up front. I actually saw the guy charging the system and I noted him recording the quantity off the charging unit display. It was 31 ounces. So, yes, it was bone dry. They put in a dye and I took it back today. Two guys went through it thoroughly and no evidence of a leak was found. They suggested I run the AC for another week and come back in for another check. I purchased a UV light and will monitor things myself. Definitely no evidence of leak from the Condenser as the lovely Toyota dealer had suggested.

In deed, it was pretty lousy that Toyota identified the issue as a 'stone/debris damage to the condenser'. I asked if they put in dye and they said, no need, we could see a stain mark. Obviously, total rubbish. They really did not check anything, just went for the easy and most expensive option. I knew it was a little fishy when two guys at the front check-in counter talked to me about possible stone damage to the condenser, even before a tech had seen the car. Hum, I said...

The crazy thing is, if I had spent the $1500 and got the condenser replaced, I would have been happy as a clam while the AC worked for say a couple of month, perhaps through the end of the summer. Next summer, when I needed it again, it would be likely out of refrigerant. Now, the car and the repair would also be out of warranty! More $s...

 

Lesson... dont trust your Dealer.

 

On the Ali Express website, my front grille is ready

 

I met the same problem with my 2020 highlander. They told me my condenser was hit by a stone and needs $1900 to get it replaced.

 

I have the same issue. So where is the leak coming from if not the condenser?

 

Hello,,I just had to spend 1,700 for the same thing!! I've never had this happen before in all my yrs driving.. My fiance's 2020 Corolla hatchback is my first encounter with this nonsense!! I've been a loyal Toyota customer for years,, owning several Toyota's.. I've never had this happen before & I'm not happy about it!! I told the maintenance team they need to figure out why this happened and why isn't the A/C condenser protected!!! Very pissed with Toyota about this!! Something needs to be done!!

 

Toyota needs a recall for this!! Because this is obviously a manufacturing problem & why should the public pay these overpriced charges!! They need to protect that A/C condenser!! And refund Toyota owner's that paid for repairs!!!!

 

My 2018 Toyota Highlander’s A/C went out recently and the Toyota dealership service dept in my town told me the same thing as most owners in this forum ”Stone damage to condenser, $1,500 repair job.” I declined and chose an approved auto repair shop. Condenser was inspected and no stone damage found. I’m considering a class action lawsuit bcas this is becoming a trend based on what I’ve read and what I’m hearing about this issue. Stay tuned!

 

I'm wondering if these condensers are succumbing to the same problem as home HVAC systems, i.e. evaporator tubes are being made so thin in the name of efficiency, (along with the increase in system pressures due to newer refrigerants being used) that 5 yr life spans are becoming more frequent on home units. The mfgs. don't want to blame the thinner walls and attribute failures to environmental factors (e.g. formaldehyde fumes in the attic!!).

 

I've never had this problem when about 20 years ago I rear ended someone and since that time leave a large space cushion and do NOT tailgate. I don't have stone chips on my windshield, hoods or AC Condensers. I see sooooooo many people tailgating all the time.

 

For the people who paid thousands, what did they actually do? The condensor from the online dealers is just over $300 and less for aftermarket. Granted a recovery and recharge can be just as much but still far less than people seem to be paying. Are dealers claiming many hours of labor to perform?

 

Hi folks, When I fired my AC for the summer, on our first 90F day, it decided to quit cooling. Nice! I took the Highlander into Toyota and even before they did a diagnostic, the service guys started talking about a potential damaged condenser and noted that if this was the case, it would not be covered under warranty. He noted he had seen this with some Highlanders... Well, after the $99 diagnostic, they rang and said, (you guessed it) it was a damaged condenser, possibly caused by hurtling stone that buried itself deep in the condenser (nah, they did not say that that but cited it could have been a stone)!

Amazing, in over 20+ years of owning various cars from the run of the mill beaters to some high end machines, this is the first time ever that I heard about a stone damaging a condenser. May be I was just a lucky son of a gun?

Anyway, I took a look around the front grill and could not see any oil stains etc?

Then went to Google and did some searches. Seems I'm not the only one to have encountered this gift with the 2020+ Highlander
2020 Toyota Highlander A/C Condenser Damage
https://www.carparts.com/blog/toyota-highlander-reliability-and-common-problems/

If this could happen even remotely, why would Toyota not simply install a mesh grill in front of the condenser to protect it? I mean, this is absurd as a condenser replacement runs at approx. $1200-1500. One of the dealers quoted $1100 and said if you need the AC gassed, that would be another $300 - I mean why in God's green earth would anyone want to replace the condenser and then not elect to put in gas for the AC!!!

Love to hear about other similar experiences? Seems there is a potential design issue here?

If you have not encountered this issue, PLESE make sure you stay well clear of stones? Stones that can put a hole in your condenser and your WALLET!

Regards....

Ask insurance to cover it - should be part of your comprehensive insurance, subject to deductible. FYI, condensers are cheap - usually around $100 - even a genuine Toyota one is around $250.
It's not a difficult job. Maybe two hrs total, plus $250 parts, and $200 for gas. Shop around. Note you CAN remove a condenser, capture the refrigerant, and reuse it - unless it all leaked out.

 

Anyone try this pre-made radiator condenser protector on Amazon? A bit expensive, though cheaper than the repairs (or even my insurance deductible.).

APS Compatible with Toyota Highlander 2020-2024 Without Camera Main Upper Stainless Steel Black Mesh Grille Insert T75041H https://a.co/d/1R5QELO

 

I bought/installed the set that was on flyaway. It was the complete set, not just the main grill. The pieces were precut and edges finished with trim. It secures with zip ties. The holes are smaller than the aluminum grill inserts I have seen. No change in temp reading and I tow a boat.

 

These are also good tips. I used the Amazon $17 material and installed it behind the grille. I also put the same material down in front of the lower valance at license plate level.

https://www.toyotanation.com/threads/protecting-the-a-c-condenser.1702308/page-2#post-14613218

 

I have a 2021 Highlander Hybrid just under the warranty cutoff. First warm day put on air conditioner and ac is blowing hot. I bring it to my local mechanic (reliable) and he tells me there is no AC in the system. He puts dye into the system to check for a leak. Holds it overnight. Finds leak in ac return line . He says it happened where the line is attached to the vehicle. Says repair and refill would be $900.00. Tells me to check with Toyota first about warranty. Go directly to Toyota, tell them the problem. They have to confirm with their own mechanics. Earliest appointment in 2 weeks. Can’t tell me whether covered under warranty. Should be interesting. Will update.

 

$900 for AC recharge ?! LOL ! That is the biggest rip off I have ever heard. Most lines will leak at the AC ports, as there is a valve inside each one.

 

Just bought Highlander XLE and after 6000 kilometres the AC failed, toyota Service says a small object (stone) damaged the tube and a small pin hole leak caused the refrigerant to leak out. Toyota says it is not covered by warranty- Toyota has a design problem with these condensers. I have had car AC for over 40 years and never had a condenser fail. I have two other cars and looked at their condenser design. Other manufacturers condenser covers the lower 1/3 of the rad rather than the 80% or so on the highlander making it more susceptible to damage, also Mazda has a metal cover in front of the tubes to protect the tubes! Honda Pilot with 275000 km - condenser is also on the lower 1/3 of the rad, again making it less likely to be damaged! Toyota says it is not a design issue and hence not covered under warranty - cost me $1730.35 for the repair. Sadly I can see it happening again, will look at a protective screen .

 

Timely demonstration of why it's so expensive to replace the damaged condenser due to the design of the vehicle.