Prius (2004-09) :: Exhaust Fumes On Startup


Mar 24, 2015

A little background on my Prius, I have an 08 that has around 179k miles on it and have never had any major mechanical problem. I have always kept up with routine maintenance. I use Synthetic oil and change it about every 6500 miles.

So, two weeks ago, it was time to change the spark plugs again. Carefully, I took out the old spark plugs and installed the new spark plugs. On the second spark plug wire and spark plug, I noticed a little bit of oil, so I wiped it off with a shop towel, installed the new plug, and kept going.

Interestingly enough, now I have a problem where when I first start my car (and only when I first start it) and I just have the interior fan running (not with the A/C on) I get some serious extreme exhaust fumes through my A/C vents and that wasn't happening before I changed the spark plugs.

Now my first thought was, "Shoot, what the hell did I do to my car?!"

Here's the weird part, once the ICE has warmed up and shut off for regular "ready" mode, I don't smell it ever again even if the ICE activates as I'm driving. Note that at this point, I haven't made any changes to what fan speed or setting the climate is on.

As soon as I turn my car back off, then back on again by pushing the power button, out comes the awful exhaust fumes again.

So, here's where the testing stage comes into play. I have tried everything I can think of. Yesterday, my father take the air box off and we made sure all of the hoses were attached and the recirculation hose didn't have a clamp. We replaced the clamp and resecured all of the hoses in the engine thinking that there might of been a loose hose with the exhaust recirculation.

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After I start the car, warm up a bit then drive, there are exhaust fumes that get into the cabin as you can smell them.

It's happening more often now. I have spoken to my Phaeton tech who said that the car has a sensor that goes off and shuts down external air if it notices exhaust uses getting in.

I have been hearing a little bit of road noise on the driver side so I'm thinking some fumes are coming in from the door seal (although it looks fine).

Sometimes it's bad enough that you have to open the windows or you will feel sick. It passes within 5 minutes or so and the car is fine after that. It only happens right after ignition for a few minutes.

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I replaced the gas cap with a brand new OEM part then cleared the CEL. However, after driving 90 miles, it went back on so I brought it to my mechanic who recommended a smoke test. After the smoke test, he said the charcoal canister and the diagnostic module needs to be replaced. Is it worth replacing to fix the CEL code and if the code is related to me smelling fumes inside the car while driving. Also, I would like to know if there might be another problem causing this code instead of the charcoal canister or the diagnostic module.

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It only happens when going up a hill when the engine is under more load than usual or under heavy acceleration. I am going to call the dealer about it and have them look at it.

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No lights on dash, but I do have emissions here so I'd like to get it fixed early 2016.

Curious what the shop charges for this install. Or if it's worth it to do both at once.

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Honda - Accord :: 2002 - Exhaust Fumes In Cabin At Idle / Stop

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At idle and while at a stop, the cabin receives a heavy dose of exhaust fumes (nope, not from the auto in front of me - I'm often alone at stop lights/signs)... what is the most likely culprit?

This did not seem to occur until AFTER I had the timing belt (package) replaced...coincidence

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Only thing though, is that this time on cold starts (as it is winter, so around -25 celcius) its really REALLY loud, like the exhaust sheared off right after the cat. However, after a few hours of driving it seems to get quieter at idle, but if you give it a little gas, it is quite audible. Also I can see exhaust fumes coming out my engine bay on said cold starts, however if I get down to ground level, I can hear it plain as day right where the pinch clamp is that connects to the catback part.

So, my theory is that, cause the bands on the clamp rusted out so my dad just put those u-bolt muffler clamps on there, which I can see an opening in the clamp, even if they're tight, until the exhaust gets hot and expands, kinda making the seal tighter but not air tight like it should. So maybe that clamp isn't doing it's job anymore and I just need a new one. OR it could be that that stupid flex pipe is broken again or that the bolts holding it to the manifold aren't tight, which that can't be cause i got them pretty snug on there. I'll have to take a look underneath again, see If I see any carbon on the exhaust, which would mean a leak, but I checked a few weeks ago and it was shiny metal, no signs of any leaks.

Car is an 04 golf with the 2.0 engine code BEV if that makes any difference. I double checked and NONE of the hangers are broken, and it's held in the right spot as it should, there looks to be no force exerted on the flexpipe at all when installed in the car, so I'm really confused.

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1) Is there a way to measure the air quality in the cabin and find out what fumes are coming in and how dangerous they are?
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