Topic: Cabin smells like exhaust

Hi,
I've had this great all original 70 bug for 5 years -- it's always smelled like exhaust but I can't find the cause.  One guy who worked on it said it was the muffler donuts -- but he was wrong, it still stinks even after he replaced them.  My clothes smell like I ran a 2-stroke motor and stood in the exhaust every time I drive it (with the windows open of course).

Any idea of what the problem could possibly be?  There aren't many aircooled mechanics in this area that I know of and the two who have worked on it haven't found the problem.

Thanks!

Re: Cabin smells like exhaust

Hi..where are you in Baltimore..I'm in Towson

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Re: Cabin smells like exhaust

Do you notice a difference in strength of odor when the heating flaps are closed completely?  Those smells can be sucked in by the engine's fan and forced through your heating system until they come out in the passenger compartment.


There are a number of places to check, starting with the integrity of your exhaust system.  That includes checking for leaks where the exhaust manifolds bolt up to the heads (front and back), muffler attaches to heater boxes (donuts) and the peashooters.

You should also check the condition of your heater boxes.  As the exhaust pipe portion of them is completely enclosed, you can have holes undetectable by visual inspection.  If they're old and crusty, you'll want to give them a real thorough going over.

The other source for smells is through holes between the engine and passenger compartments.  There should be a fabric sound barrier (looks kinda like a bean bag) jammed between the inner and outer body metal in the upper left/right corners of the engine compartment.  Not only do they provide some sound deadening, they also prevent fumes from drifting up. 

Less likely sources are rust holes, or holes drilled to pass wires or whatnot through.

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Re: Cabin smells like exhaust

Baltimorebug wrote:

Hi,
I've had this great all original 70 bug for 5 years -- it's always smelled like exhaust but I can't find the cause.

In addition to what "Der Bugmeister" mentioned...some questions:

- What sort of exhaust system do you have (stock or aftermarket)?
- What sort of condition is your bug's exhaust system in (new, old, don't know....rusty, not rusty, etc.)?
- Do the tips of the exhaust extend beyond the body of the car (in the rear)?

- Nick

1979 Super Beetle Convertible

Re: Cabin smells like exhaust

I'd agree that the heater flaps are first suspect, as if they are closed tight it's hard for fumes to get to the passenger area. Unless... the hoses that go from the heater boxes to the passenger area are missing. If so any fumes under the car can enter the passenger area regardless of all else.

Also, is all the engine tin in place with good seals so that the upper engine area is sealed from the underside where the exhaust is located? The engine fan pulls in air from the upper compartment, and if the tinware seals are missing exhaust can migrate up and mix in. But if the heater flaps close tight and the heater hoses to the body are good, it should still be tight if the heater is off.

Re: Cabin smells like exhaust

Hi, thanks for the feedback on the exhaust smell.

The car's a '70 Bug, totally original.  Not a speck of rust on the underside, only surface rust on the body.  The exhaust is stock.  It looks to be okay -- muffler is in good shape, but I can't see anything beyond that.  The tailpipes do extend beyond the body.  All of the engine tin is in place; the last mechanic inspected the exhaust (only what he could see I guess) and said it was donuts.

There is a haze that covers the windshield over time, so I suspect it's coming in through the defroster\fresh air ports as well.

It's frustrating because it's a great drive in every other way.

Any ideas for aircooled mechanics in the central Maryland region?  Much appreciated.......

Re: Cabin smells like exhaust

See this part:

http://www2.cip1.com/v/vspfiles/photos/VWC-043-255-108-DX-2T.jpg

This is called a "heater box".  There's one on each side of the engine.  They mount to the cylinder heads.  In the photo above...the muffler connects to the "heater box" on the right...and a flexible hose connects to the heater box on the left (which sends warm air to the inside of the Beetle).

The way this works is...the heater box is basically a "J" tube with sheet metal surrounding it.  The "J" tube gets hot from exhaust gases...and fresh air is blown on the outside of this hot "J" tube.  This warms the fresh air...and this is how you get "heat" inside the Beetle when it's needed.

I'm explaining this because there is a very close association between the exhaust system & the heating system in a Beetle.  If everything is not in tip-top shape..."cross-contamination" so to speak can occur...thus you can get exhaust fumes/smell in the inside of the Beetle (from any of the heater vents...back seat, footwell in the front floor, or the defrosters).

Basically someone needs to get under the car...make sure all appropriate parts are present (not missing)...and are functioning properly.  It would also be a good idea for an experienced/knowledgeable person to get under the car (while it's running) to feel/inspect for exhaust leaks to help pinpoint possible leakage areas.

HTH,

- Nick

1979 Super Beetle Convertible