GM Service Manual Online
For 1990-2009 cars only

Information on Hot Plastic Odor Emanating from Exhaust During Initial Run-In of Vehicle - No Fix Required

Subject:Information on Hot Plastic Odor Emanating from Exhaust during Initial Run-In of Vehicle -- No Fix Required

Models:2007 Cadillac Escalade, Escalade ESV, Escalade EXT
2007 Chevrolet Avalanche, Suburban, Tahoe
2007 GMC Yukon, Yukon XL, Yukon Denali, Yukon Denali XL



Some owners may comment on a "hot plastic" odor emanating from the vehicle exhaust system during the first 80 km (50 mi), or the first day or two of ownership.

This odor has two sources:

    • The primary source is from a special roving material used inside the exhaust muffler for Active Fuel Management™ (AFM) noise attenuation. The roving material has manufacturing/processing adhesive retainers applied to it in order to facilitate assembly of the muffler. The odor is from these retainers oxidizing away due to exhaust system heat.
    • The secondary source is from the environmentally friendly production part identification labels oxidizing away due to exhaust system heat.

DO NOT REPLACE ANY EXHAUST SYSTEM COMPONENTS IN AN ATTEMPT TO CORRECT THIS CONDITION.

Once the retainers and labels have oxidized, the odor will be eliminated.