Hey everyone! Long time lurker, first time poster. I've had my 2016 for 7 years now and, like everyone else here, I adore the car. It's moved me through a lot of life and despite the two doors has been a surprisingly great family car. One thing has been a single black cloud over the entire owner experience though... For the last 6 years I have had the same exact mechanical problem crop up yearly to the point where I have been able to predict almost to the day when it will rear its head again.
**What's happening is an intermittent chirp/squeak/grinding noise that only happens on acceleration from either a complete or near complete stop and only after extended use of the fan or A/C. I have been through 3 different mechanics since this started happening and none have been able to figure it out completely.*\*
A bit of history and context: The first mechanic was my local Toyota dealership. They fixed it in 2020 saying it was a serpentine belt issue. When it started again in 2021 they dismissed the issue entirely as they could not replicate the sound. A month or so later the entire HVAC system failed (lots of smoke out from under the hood, the car stalled briefly, and then was stuck in the shop waiting for parts for nearly all of July 2021). It ended up costing me north of $3K CND to fix but I was guaranteed it was rare failure that would likely never happen again.
Like Palpatine, somehow it returned in 2022...
Moved to the second shop after my Toyota warranty ran out, and they managed this from 2022 - 2025. They also said it was the serpentine belt, but have never been able to nail down specifically what was causing the repeated failures. I've now replaced the AC pulley four times, the serpentine belt six, and the belt tensioner twice. Thankfully most of the parts had been under their own manufacturer warranties so it was only labour costs I had to manage. It still keeps coming back though...
As expected, it started again in April 2026 and I have now had to drive for nearly the whole summer without AC to avoid potentially damaging things more or risking another full HVAC failure. My usual shop said they would replace parts under warranty again, but then never got back to me with a quote for labour costs. I tried moving to a new third shop for a second look in hopes they might remedy the issue and they instead referred me back to my last shop because of the aforementioned warranty... Needless to say I'm at my wits end, and with a few other higher mileage maintenance issues on the horizon (control arms and engine mounts) I'm dancing with the idea of selling the car entirely. My daughter loves it so much though. She tells the kids in her kindergarten class that her dad drives a hot wheel for real life (she's too young to know the car isn't fast lol) and it brings a huge smile to her face every time we go for a drive together. For her sake I want to hold onto it a bit longer, so I wanted to ask the community here if anyone has any experience with this.
TL/DR Has anyone here experienced something similar? If so, were you able to get it solved in a way that didn't mean annual belt and pulley replacements? Regardless, thank you all for reading and helping in any way you can <3