hatteras8926 wrote:
The old sensor would smoke and make one of the most acrid smells ever. The best I can describe the smell would be similar to school bus exhaust. It used to be that I would have to turn off any A/C or heat when I came to a stop so that the smell would not come into the cabin, but it recently started seeping in even when I would turn the climate controls off. I never had a CEL or other idiot light turn on, and there have been no other noticeable issues. As I stated, I just replaced the oxygen sensor today. The new one also smokes and smells.
Any ideas?
Your valve cover gasket(s) is leaking oil - a common problem with the 3.7 engine.
The gasket leaks at the bottom, rear-most point against the firewall. If you look at the bottom bolt and follow it directly down you can see that a drop (drips) of oil will land directly on the hot catalytic converter instantly vaporizing the oil (that's why you never smell the smoke when the Jeep is cold.) And your cabin intake is at the base of your windshield right above where the smoke originates. Hence, when you come to a stop your HVAC system sucks in the smoke and blows it right in your face. Not pleasant...
The problem may be happening on both sides though not as bad on the driver's side - yet. A set of gaskets from the dealer will run you around $50 or get Fel-Pro gaskets from NAPA or other parts stores. The project can be done at home. The passenger side is tougher because of the coolant reservoir and water pipes for the heater. The A/C lines won't be a problem.
Remove the hoses from the coolant tank, plug them and remove the nuts holding the tank to the firewall and put it aside. Remove the two bolts that hold the oil fill spout in place; disconnect the supply and return lines to the heater core. With the oil spout removed the pipes can be moved out of the way.
Then go about loosening the bolts holding the valve cover in place and pry it out of the way. There are clips on both sides that hold wire harnesses in place; you'll need to pull those clips off the valve cover bolts and move the harnesses out of the way. Take off the gasket and scrape any crud off the head and cover; use the new grommets that come with the gaskets.
Unfortunately you replaced an O2 sensor that was fine. But the good news is your catalytic converters aren't the problem.
Keep us posted!
Bob