EXHAUST SULFUR ODOR AFTER HARD ACCELERATION – CLIMATE CONTROL IN RECIRCULATION MODE ONLY

[WWWPerfA_ZN0W]

TSB 14-0201

EXHAUST SULFUR ODOR AFTER HARD ACCELERATION – CLIMATE CONTROL IN RECIRCULATION MODE ONLY

Publication Date: October 28, 2014

FORD: 2011-2014 Edge
LINCOLN: 2011-2015 MKX

ISSUE:

Some 2011-2014 Edge and 2011-2015 MKX vehicles may exhibit an exhaust odor in the vehicle while the climate control system is in recirculation mode only. This may be more noticeable after hard acceleration, driving in hilly conditions and/or towing a trailer. Customers may indicate the odor smells like sulfur.

ACTION:

Follow the Service Procedure steps to correct the condition.

SERVICE PROCEDURE
1.Remove the rear bumper. Refer to Workshop Manual (WSM), Section 501-19.
2.Replace the four (4) air extractors.
3.Lower and support the rear section of the exhaust system.
4.Clean the areas on the underside of vehicle where seam sealer and expandable foam will be applied. (Figures 1-6)
5.Cover the exhaust system.
6.Apply a generous amount of Motorcraft® Seam Sealer to the rear horizontal sheet metal lap joints on the left and right sides of the vehicle and the rear sheet metal overlap flange across the rear of the vehicle. (Figures 1-6)

Figure 1 – 14-0201

Figure 2 - 14-0201

Figure 3 - 14-0201

Figure 4 - 14-0201

Figure 5 - 14-0201

Figure 6 - 14-0201

Figure 7 - 14-0201
7.Fill crush cans with Lord Fusor 130 or 3M 08458 expandable foam. Follow the instructions on the can for application. (Figure 7)
8.Install foam from the Rotunda Squeak and Rattle Repair Kit (164-R4901) around the bumper beam attachment studs. (Figure 8)

Figure 8 – 14-0201
a.Some vehicle configurations may have unused bumper attachment studs on each side of the vehicle. Apply Motorcraft Seam Sealer around unused studs. (Figure 8)
9.Reinstall the rear exhaust system.
10.Reinstall the rear bumper cover. Refer to WSM, Section 501-19.
11.Reprogram the heating ventilation air conditioning (HVAC) module to the latest calibration using IDS release 92.04 or higher. Make sure you are connected to the internet when entering module programming to obtain the latest updates. Calibration files may also be obtained at www.motorcraftservice.com.

Obtain Locally
Part Number Part Description
130 Lord Corporation Fusor® Rigid Foam (Super Fast)
08458 3M Rigid Pillar Foam

PART NUMBER PART NAME

AL2Z-61280B62-A Grille – Air Inlet
TA-2-B TA-2-B Motorcraft® Seam Sealer

OPERATION DESCRIPTION TIME

140201A 2011-2014 Edge, 2011-2015 MKX: Seal The Body Includes Time To Replace Air Extractors And Reprogram The HVAC Module (Do Not Use With Any Other Labor Operations) 1.8 Hrs.

WARRANTY STATUS

Eligible Under Provisions Of New Vehicle Limited Warranty Coverage.
Warranty/ESP coverage limits/policies/prior approvals are not altered by a TSB. Warranty/ESP coverage limits are determined by the identified causal part and verified using the OASIS part coverage tool.

DEALER CODING

BASIC PART NO. CONDITION CODE

61280B62 34

[omar302]

Thanks a lot

 

Here is a PDF version of the same:

 

TSB 14-0201 - Exhaust Sulfur Odor after Hard Acceleration – Climate Control in Recirculation Mode Only.pdf

[omar302]

They tried to fix this on my MKX, it is ~80% better. Still some slight smell is present, though not nearly as bad as before & I might be confusing it for outside air since the TSB involves reprogramming of the Climate Control possibly to turn off recirculation during hard acceleration. But when I tried to glance through the paper work, it seems they applied a newer TSB (starts with 15-XXXX) and it also involved replacing the exhaust tips with a newer version that has the exhaust gas outlet exiting downwards but with the chrome "oval" tip still looking the same. It is now a truly fake exhaust tip.

 

 

 

Note: I recently saw a 2015 MKX in a showroom & it still had the old type exhaust tip, so this TSB might be very new & not in production vehicle.

[WWWPerfA_ZN0W]

Sucks they had to ruin a perfectly good looking exhaust tip, but I suppose if it works, it's a cheap fix ANYONE can do.

[omar302]

Any updated TSB for this? The smells seems to have come back, or become more apparent recently.

[WWWPerfA_ZN0W]

None that I can see

[remsleep]

I have Ford Edge 2015 after my complaint dealer said nothing find

[omar302]

Finally was able to get a copy of the latest TSB (attached) for this issue & it seems to be a good update on the previous one including a pressure test. Already talked to my dealer to get my car back to redo parts of the TSB is it is very clear it was not done properly. Hope they'll fix it good this time.

tsb15-03-NA.pdf

[WWWPerfA_ZN0W]

An update in the case of the Explorer, may help with the Edge as well

 

EXHAUST ODOR IN VEHICLE
Publication Date: December 15, 2016

FORD: 2011-2015 Explorer

This article supersedes TSB 16-0165 to add a causal basic part number and condition code.

ISSUE:

Some 2011-2015 Explorer vehicles may exhibit an exhaust odor in the vehicle with the auxiliary climate control system on. Customers may indicate the odor smells like sulfur, or that exhaust odors are entering the vehicle cabin. This condition may be worsened when the climate control system is in recirculate mode and the vehicle is heavily accelerated for an extended period. Whether and to what extent any customer or occupant of a 2011-2015 Explorer vehicle experiences the exhaust odor will be affected by driving habits, weather and individual sensitivities.


ACTION:

Follow each and every step of the Service Procedure in procedure 1 to improve the condition.
SERVICE PROCEDURES

Note: The Service Procedure consists of 2 separate repair routines. Most vehicles will not require the second procedure.

Procedure 2 does not apply to vehicles equipped with the 2.0L Gasoline Turbocharged Direct Injection (GTDI) and 3.5L GTDI engines.

Note: The body sealing steps in this procedure are critical elements in helping to manage subjective odor concerns.

Is the customer returning with the exhaust odor complaint after Procedure 1 was completed?
No – proceed to Procedure 1.
Yes – Is the vehicle equipped with the 3.5L Twin Independent Variable Cam Timing (Ti-VCT) engine?
Yes – proceed to Procedure 2.
No – the procedure does not apply. Continue with normal diagnostics.


PROCEDURE 1

1. Reprogram the heating ventilation air conditioning (HVAC) module to the latest calibration using IDS release 101.03 or higher. Make sure you are connected to the internet when entering module programming to obtain the latest updates. Calibration files may also be obtained at www.motorcraftservice.com.
When reprogramming the HVAC, IDS will have additional questions which will require a yes response to reprogram the module.

2. Remove the rear bumper cover. Refer to Workshop Manual (WSM), Section 501-19.

3. Remove the left and right tail lamps. Refer to WSM, Section 417-01.

4. Remove the wheel lip mouldings. Refer to WSM, Section 501-08.

5. Open the liftgate and inspect for presence of drain valves in the two (2) drain holes on the left and right side of the liftgate. Are the drain valves present? (Figure 1)
drain valve
Figure 1

Yes – proceed to Step 7.
No – proceed to Step 6.

6. Install a new drain valve in each of the two (2) drain holes on the left and right side of the liftgate. (Figure 1)

7. Inspect the liftgate seal for damage and proper fit/contact pattern. Adjusting the rear liftgate striker so that the rear hatch seals tighter to the liftgate seal is important. This can be done by loosening the striker and moving it to increase the liftgate sealing pressure.

8. Inspect the left and right side air extractors for proper fit to the body and operation/sealing of the rubber flaps.
Replace the air extractor if it is warped or damaged or flaps do not lay flush to their sealing surface. (Figure 2)

air extractor Figure 2


9. Inspect and verify proper installation of the wire harness grommets and body plugs in the liftgate opening, quarter panels under the tail lamps, license plate and bumper cover and the rear underbody area.

10. Using masking tape, seal the left and right air extractor vents and the rear auxiliary climate control drain tube.
Make sure to tape off only the vents and not the area around the air extractor where it seals to the body of the vehicle.

11. Start the vehicle and set the front climate control to fresh air mode and front blower speed to HI. Turn the rear climate control off.

12. Make sure all windows are up and all doors are closed in order to pressurize the cabin.

13. Use soapy water (dish soap or bubble bath works best-not bar soap) in a spray bottle to help locate air leaks.
Spray the underbody seams, rubber grommets, rear wheel well seams, tail lamp seams, liftgate seals, quarter glass seals, license plate area, liftgate hinge area, auxiliary a/c seals and the area where air extractors mount in the body.

14. Air leaks will be identified by the presence of air bubbles. Mark the location of any leaks.

15. Turn off the a/c and shut the vehicle off.

16. Clean and dry all marked areas and seal using Motorcraft Seam Sealer.

17. Raise the vehicle on a hoist. Refer to WSM, Section 100-02.

18. Lower and support the rear section of the exhaust system.

19. Clean areas on the underside of the vehicle where seam sealer will be applied. (Figures 3-5)

areas on the underside of the vehicle where seam sealer will be applied Figure 3

areas on the underside of the vehicle where seam sealer will be applied Figure 4

areas on the underside of the vehicle where seam sealer will be applied Figure 5


20. Cover the exhaust system and verify the auxiliary climate control drain tape is still in place.

21. Apply a generous amount of Motorcraft Seam Sealer to the following areas:
The rear horizontal sheet metal lap joints on left and right sides of the vehicle.
The rear sheet metal overlap flange across the rear of the vehicle. (Figures 3-5)

22. Spray a generous amount of 3M Rubberized Undercoating around the auxiliary air conditioning lines and seam sealer areas. (Figure 6)

auxiliary air conditioning lines Figure 6


23. Remove the tape from the air extractors and auxiliary climate control drain.

24. Install the rear exhaust system.

25. Install the wheel lip mouldings. Refer to WSM, Section 501-08.

26. Install the rear bumper cover. Refer to WSM, Section 501-19.
Apply masking tape around the outer edge of the rear fender mouldings to protect the vehicle from damage.

27. Install the tail lamps. Refer to WSM, Section 417-01.

28. Is the vehicle equipped with the 3.5L Ti-VCT engine?
Yes – return the vehicle to the customer for evaluation, close out the repair order and submit the claim for payment.
Procedure 2 can be performed if the customer returns with the same complaint.
No – return the vehicle to the customer, close out the repair order and submit claim for payment.
Procedure 2 does not apply to the vehicle.


PROCEDURE 2

1. Guided Routine Click here to access Guided Routine. Does the vehicle meet necessary conditions?
Yes – proceed to Step 2.
No – return vehicle to the customer. No additional repairs are available.

2. Inform the customer of the redesigned exhaust tips and that appearance will remain the same but the exhaust will exit the tip from bottom. Upon acceptance, replace the muffler assembly with the updated part containing the down turned exhaust tips. (Figures 7-8)

exhaust tips Figure 7

exhaust tips Figure 8


3. Return the vehicle to customer.

Obtain Locally
Part Number Part Description
08883 3M Rubberized Undercoating

PART NUMBER PART NAME
BB5Z-61280B62-B Dual Rate Air Extractor
BB5Z-7829164-AA Wheel Lip Moulding Right Side
BB5Z-7829165-AA Wheel Lip Moulding Left Side
4M8Z-54280B62-A Valve Assembly Auto Drain
TA-2-B Motorcraft Seam Sealer
EB5Z-5230- A Muffler Assembly

OPERATION DESCRIPTION TIME
160166A 2011-2015 Explorer 3.5L Ti-VCT: Perform Web Assessment, Obtain Repair Verification Code (RVC) And Replace The Muffler Assembly Following Procedure 2 (Do Not Use With Any Labor Operations Outside Of This Article) 0.7 Hr.
MT160166 2011-2015 Explorer: Reseal The Body Following Procedure 1 Includes Time To Reprogram The HVAC Module (Do Not Use With Any Labor Operations Outside Of This Article) Actual Time

WARRANTY STATUS

Eligible Under Provisions Of New Vehicle Limited Warranty Coverage.
Warranty/ESP coverage limits/policies/prior approvals are not altered by a TSB. Warranty/ESP coverage limits are determined by the identified causal part and verified using the OASIS part coverage tool.

DEALER CODING
BASIC PART NO. CONDITION CODE
61280B62 42

[vmaxbaby]

After all these years you would think there wouldn't be issues like these.  I figure for the edge st sport or st I figure it was to speed things up on the assembly line.  But the price we pay for vehicles I wish they wouldn’t make all these short cuts to save a dime but that is the world we live in :(  

[Davidg716]

My new 2020 Edge has this issue too. I cant believe after nearly 10 years they still havent fixed this issue.

Edited April 15, 2021 by Davidg716

[enigma-2]

You have a 2020 or read about it somewhere ? 

Yea, it IS incredible !

[Davidg716]

On 4/7/2021 at 8:50 PM, enigma-2 said:

You have a 2020 or read about it somewhere ? 

Yea, it IS incredible !

I have a 2020. It's got less than 1k miles on it and I noticed it as soon as I got on the interstate. My 2017 edge had the same issue.