Punctured A/C Condenser

Just got off the phone with Porsche Cars NA and they tell me that to date I am only the second person in the country who has had this happen....I don't believe it. As I recall when this happened to me last summer there were several folks on this site who said that it happened to them. There is NO shield, and one rock is fatal to the unit. The fix is around $1,200, not covered under warranty. OUCH. What really p's me off is when they said, no, they did not intend to offer a retro-kit and provide better protection for either current clients or future designs. Not what I've come to expect from this car company. Chine in if this happened to you...thanks!

Ouch! is right . . . Won't your car insurance company cover it (just like if a rock broke your windshield)? BTW, where is the condenser located?

I believe that was another web site that had a small discussion about that. One person if I recall had a similar issue. Agree this should be covered by your auto policy.

It's damage that should be covered under the comprehensive portion of your auto insurance policy. The condensor has been where it is for at least ten years (it hasn't moved since the original Boxster design) so Porsche 's not going to move it now. If you want to see an example of something else they know is an issue but haven't done anything about, note the warning in the manual about not throwing a cigarette butt out the window lest it be sucked into the air intake and start the engine compartment on fire. That's great, but more than one Boxster owner has had a butt tossed by a driver ahead of them in traffic turn their car into a car-b-que…

Thanks, guys. Couple of things..... The a/c condensor is in the right front air scoop. I am not suggesting they move it; what would make sense is to put a heavy screen in front of it to keep rocks from puncturing it. There seems to be a lot of agreement that this is an oversite, even at the dealership level. Insurance yes, insurance no. First, I have a $1,000 deductable, not $500. In Massachusetts it's about a $250/yr savings, in other words, you can crash the car every two years and break even. Only a fool would have a $500 deductable in this state, or they DO crash a lot! Four years ago I did about $1,700 worth of damage to my E36 M3 (drove into the garage with a bike on the roof rack!). My insurance agent recommended I file. I got a check for $700. Whoopie. I then got 5 pts added to my driver's record, and pay an extra $340/yr in premium as a result, for five years. So, that $700 cost me $1,700 to get. Hmmm. If the agent wasn't a good friend of mine, and fellow club racer, I'd have sacked him...as it was I tore him a new one! :argue:

Added Screens When I first got my car, someone else on this board (was it you?) posted that he'd had his AC fail on the way home from a DE, and that this was likely caused by a stone through the condenser while on the track. Before I went on my first DE I got a clear bra - AND screens put in to ward off most of the ****. I noticed at the time, after only two months of ownership, that there was bunch of stuff in there already, and more than a few dings on the condenser from stuff blowing in. The screens are not 100% protection, but for a few $$, they'll take care of MOST of the junk - and in CA, there's a LOT of junk on the roads!

Can you remember where you got the screens? I think there might be quite a few members who would want to consider them.... Thanks!

Had them made up by a body shop - EMC in Fremont, CA. Just some expanded steel mesh, painted and baked black.

Is this it? What caused you to know it was punctured? How much is the part alone?

Thanks very much! I'll have to check them out. Hopefully this info will be helpful for quite a few members...it's an expensive lesson to learn. In fact, the site organizers might even want to think about some sort of "sticky" notice, something along the lines of: "Strongly Recommended Retro-Fits"...or some other not-uncertain terms.... Thanks again, everybody....

gutter guard works well but there is a mesh that has bigger holes and looks nicer. Paint them black and you'll hardly see it

This happened to me last week.The Dealer said "IT WAS NOTALL THAT UNCOMMON",and they keep condensers in stock for that very reason. Seems ridiculous to not spend a few dollars to avoid a $1000+ repair job. If you haven't looked at your condenser location, please do your self a favor and take a look. Then see how EZ it would be for a flying object to enter this area. May not be common but it is $1000+ gamble.Good money for Porache too.

This just happened to me last week and cost me the $1200 everyone else has paid. I brought it in thinking it was a normal AC compressor leak and walked out $1200 poorer. Is there really nothing we can do on this with Porsche USA? I was going to call them but it sounds like it may be a waste of time. I'll put some mesh screens on there now but I wish Porsche would have done something to fix this at the factory!

I am at a loss as to why the A/C Condenser was not repaired, you would not throw away a radiator for a puncture. My dad owned a radiator & A/C repair and wholesale distribution business and as I recall damaged radiators and condensers were thought to be the easiest repairs made. Someone please fill me in as to why they are a throw away now. I know condensers are made of aluminum, but aluminum is regularly welded in my experience.

today I had Sharkwerks (a great company to deal with) install grill screens. They put them recessed behind the bumper cover. Much more ascetically appealing to me than installing them right behind the bumper cover. The screens are mounted to the black plastic material that funnels air to the air conditioners/radiators (radiators behind A/c condenser ) All the function and none of the exposed zip tyes! Thanks Dan/Alex/James! Sharkwerks Rocks!!!!

Thanks so much jurnes and honestly a real pleasure. Your car sure does surprise a few at the track although that has to be driver too The screen place you found online was really a great find... We bought some just to have it here so we could do them for all sorts of cars if need be

Condenser replacement This post, I hope, will stimulate some preventative actions. I too have just suffered a punctured condenser. The reason of course, is that the condensers are right in the line of fire for any stone that happens to shoot through the front intake! The lack of a suitable front grille to protect against this is a major omission from Porsche. I have subsequently purchased two very nice black grilles from Zunsport.com (in the UK). When (its only a matter of time) this happens to you - you will be confronted with an enormous bill if you go to your dealer - upwards of GBP£1300. Even a porsche indepent specialist quoted me GBP£650 all in. So, I decided to tackle the job myself - after all how hard can it be? Actually, it is very easy. All you need to do is remove the front bumper, unscrew the condenser, clear out all the debris that has accumulated over the years, refit a new condenser, refit the front bumper, and then go and get your A/C serviced and re-gassed. Since taking the front of your beloved Cayman may seem daunting, see below for instructions. Sorry for no photos, but I am not able to multi-task! 1. Removal of front bumper. First, jack up the front of the car, insert two jack stands on each of the front axles and make safe. This will give you room to work. Open the front boot and remove the plastic/rubber cover around the release handle. This was attached by velcro on my car, so simply required pulling off. Then simply unscrew all the screws that connect the front bumper to the car (two screws). Then remove all of the screws on the underside of the bumper (cant remember how many). You also need to remove the inner mud guards from the wheel arches - just the larger lower one, from each side. This is more fiddly, but by moving the front wheels, you can simply unscrew the retaining screws and jiggle to take completely off. Now, you need to pop the indicator lights out of their housings - simply done by reaching behind the light and pressing the spring catch. This will reveal another retaining screw, which you should unscrew. Behind the right hand indicator (on my UK car) is a wire loom and connector which feeds the electrics to everything on the bumper. Simply disconnect this by pulling apart at the connector point. Now you only have two more retaining clips to deal with which connect the top of the bumper at the front to the body of the car next to each headlight. They can be accessed from the front boot area. The clips simply pull out completely. Take care here as my clips snapped - not a problem as they still worked fine. Now you should be able to remove the front bumper completely. Do so and place the bumper somewhere safe - to prevent it getting knocked and damaged. 2. Removing the condenser The condensers are located behind the plastic/rubber housings to either side of the front of the car. There are two screws on each housing that need to be removed - one recessed and one underneath. There are two retaining clips to the side of each housing which need to be unclipped. Take care here - I broke the lower clip on each side (when I refitted I drilled two small holes and secured using a plastic tie). Remove the housings. You should now see the condensers and probably a lot of leaves, dirt and stones! Clean out as much of the debris as you can - I used a vacuum cleaner with brush attachment - you will need to revisit this when you remove the condenser as more dirt collects between the condenser and the radiator behind it. The condensers are attached to the air conditioning system via two allen key bolts. Unscrew the bolts carefully. Two of mine were very difficult to take off and I had to replace them. Also, when removing the connecting housing, take great care not to spoil the washers that make the seal with the air con system. Now remove the retaining screw, connecting the condeser to the car. Remove the condenser completely and clean the debris behind it. You are now set to install the new condenser and refit the housings and bumper. Simply follow the above instructions in reverse. It is recommended - but not essential - to fit two new condensers on the basis that accumulated debris will eventually cause the condenser to perish. Both my condensers showed signs of stone hits, so although only one had a hole in it, I thought it best to replace both - just to be on the safe side. I picked up two new condensers from ebay at a cost of GBP£135 each! 3. Service and re-gas Once you have reassembled the car, you will need to get the air con system tested (for leaks), serviced (moisture removed and oiled) and regassed. Any garage offering air con service should be able to do this. I got mine done locally for GBP£80 all in. 4. FIT NEW PROTECTIVE GRILLES Of course, all the above could be in vain if you dont fit protective grilles to prevent this from happening again!!! I hope that this is helpful. It really isnt that difficult to do and it will save you a shed load of cash compared to getting it done at your dealer.

Re: Condenser replacement Can you add photos to this and make it an article in our Articles section please? That's what it is there for and this is a prime candidate!

Just did the screen mod--easy and even enjoyable. What's the susceptibility of the oil cooler (on driver's side) from being punctured in this manner?

A/C condenser damaged by rock..$900 A rock has hit my A/C condenser. Dealer wants $900 to repair. I have made a claim at my insurance...fingers crossed I hope this does not cause my rates to go way up.After a quick search.... It seems this has happened to many....it's a shame Porsche doesn't find a cure for this.:crazy:

Re: A/C condenser damaged by rock..$900 Motordrive makes grills to greatly reduce the chance of this happening. Since this is not warranty work, why don't you find out a trusted independent mechanic ang give him a chance to quote? Your local PCA club is usually a good place to ask.

Re: A/C condenser damaged by rock..$900 I had thought it was a warranty issue.....I did not know a rock had done the damage. So after going to dealer and having to pay a 2hr diagnostic fee....my independant shop was only $100 less. The indy shop didn't have the condenser in their inventory....the dealer did...made the choice to leave the car overnight. I will find out today if my the flying rock is covered by my insurance policy... I will put a screen over the condenser....Porsche should have done this:crazy:

Add me to the list.....my Porsche dealer did do the work for $900 instead of $1200... I still believe Porsche should have done a better job! It's a wimpy design at best. Shame on you Porsche ...:gossip: Well...I feel better now to have vented...but my wallet is lighter. Just found this thread...sorry to have posted another...mods..feel free to delete most recent thread.

Thread merged. Sorry to hear about your troubles trapper ! I purchased and installed grills from j_copeland just to prevent something like this. http://www.planet-9.com/cayman-boxster-modifications/50393-front-grill-mesh-installed-photos.html

Or go to Home Depot and get some aluminum mesh.

Thanks for the advice guys. I went with j_copeland. I could have saved a few dollars and took the Home Depot route...but decided to save myself some time and effort and go pre-cut. This should be a sticky. Very first mod for everyone. Porsches can slide around the race track or down the highway...just make sure and use the fast steering response to dodge any little rocks that might fly up into your grill. Or keep an extra 1k in the glovebox for repair.:crazy:

It's my understanding that this would be an insurance claim, less deductible of course, just as a broken windshield is if broken by a stone. Check with your insurance company.

It just happened to me, on my 2018 Cayman S (982). Dealer said it could not be repaired. Estimated $1400 to repair. Plus $395 to recharge with very expensive coolant. Filed an insurance claim.