why does my Ford Explorer Fifth Generation (2011-2019) have an exhaust smell in the cabin?

Ford Explorer Fifth Generation (2011-2019)

Error Codes

2-4 hours

Time

medium

Difficulty

medium

Severity

4 min read

640 words

Problem Statement

Learn how to diagnose and fix exhaust smell in the cabin of Ford Explorer (2011-2019). Step-by-step guide with symptoms, diagnostic steps, and repair instructions.

Affected Component

Exhaust System

Estimated Time

2-4 hours

⚠️ Safety Warnings

Important safety information - read before proceeding

•Disconnect the battery before working on electrical systems.
•Allow the engine to cool before inspecting the exhaust system to prevent burns.

Symptoms

•Exhaust odor noticeable inside the vehicle
•Increased cabin noise when accelerating
•Presence of exhaust fumes near the engine bay
•Poor air quality inside the cabin
•Possible check engine light illuminated

Diagnostic Steps

1
Inspect the exhaust system for visible leaks, including cracks or holes in the exhaust pipes and muffler.
2
Check the condition of the exhaust manifold and any associated gaskets for leaks.
3
Examine the cabin air filter to see if it is clogged or damaged, which might allow exhaust fumes to enter.
4
Verify that the cabin ventilation system is functioning correctly and that the recirculation mode is not stuck.
5
Use an OBD-II scanner to check for any error codes related to the exhaust system or emissions.

Solution

💡 Expert Tip

For complex repairs like this, consider taking photos at each step. This helps if you need to reverse a step or consult with a mechanic. Also, keep all removed parts organized - you may need to reference them during reassembly.

Verification

After completing the repair, verify that the issue has been resolved:

✓Test the affected component to ensure it functions correctly
✓Check for any error codes or warning lights
✓Monitor the vehicle for a few days to ensure the issue does not recur

Prevention Tips

To prevent this issue from occurring again:

•Follow the manufacturer's recommended maintenance schedule
•Address warning signs early before they develop into major issues
•Use quality parts and fluids recommended for your vehicle
•Keep detailed records of all repairs and maintenance

Tools & Equipment Required

•Jack and jack stands
•Wrench set
•Flashlight
•Torque wrench
•Socket set
•Screwdriver
•OBD-II scanner

Parts Required

•Exhaust manifold gasket (if applicable)
•New cabin air filter
•Exhaust pipe/muffler sections (if damaged)

Related Faults

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Diagnostic Steps

1
Inspect the exhaust system for visible leaks, including cracks or holes in the exhaust pipes and muffler.
2
Check the condition of the exhaust manifold and any associated gaskets for leaks.
3
Examine the cabin air filter to see if it is clogged or damaged, which might allow exhaust fumes to enter.
4
Verify that the cabin ventilation system is functioning correctly and that the recirculation mode is not stuck.
5
Use an OBD-II scanner to check for any error codes related to the exhaust system or emissions.

Solution

1. Preparation

Gather tools and parts needed for the repair.
Ensure the vehicle is parked on a flat surface, and apply the parking brake.
Disconnect the battery to avoid any electrical issues.

2. Inspect Exhaust System

Sub-steps:
- Raise the vehicle using a jack and secure it on jack stands.
- Visually inspect the entire length of the exhaust system from the engine to the tailpipe.
- Use a flashlight to check for cracks, rust, or holes in the exhaust pipes and muffler.
- If leaks are found, proceed to replace the damaged sections of the exhaust system.
Tools Required:
- Jack and jack stands
- Wrench set
- Flashlight

3. Replace Exhaust Manifold Gasket (if leaking)

Sub-steps:
- Remove the heat shield (if applicable) to access the exhaust manifold.
- Disconnect any necessary components to remove the exhaust manifold, including any electrical connectors or brackets.
- Remove the old gasket and clean the mating surfaces on the engine and manifold.
- Install the new gasket and reassemble the exhaust manifold, ensuring all bolts are torqued to the manufacturer's specifications.
Tools Required:
- Torque wrench
- Socket set

4. Inspect and Replace Cabin Air Filter

Sub-steps:
- Locate the cabin air filter compartment, usually behind the glove box or under the dashboard.
- Remove the filter cover and take out the old cabin air filter.
- Inspect the filter for dirt and debris; replace it with a new one if necessary.
- Reinstall the cover securely.
Tools Required:
- Screwdriver (if needed)

5. Test Ventilation System

Sub-steps:
- Start the vehicle and turn on the HVAC system.
- Cycle through the different ventilation settings (defrost, floor, etc.) to ensure proper operation.
- Check for any unusual noises or smells emanating from the vents.