strong chemical smell suddenly appears in 2002 windstar

[schadd1971]

Hi, this one blows my mind....my wife goes to get in our van one morning and opens the door and the van has a VERY strong smell...she calls me and said it smells like something burning....so Im thinking an electrical issue...but on getting home I open the doors and it seems to me it smells more chemical...she said it not as strong as first.( maybe because the van was shut up all night...)...the van was totally fine the day before...the smell is odd...not coolant.( have had plenty of heater core leaks in my life...coolant on the floor,steamed up windows,sweet smell of hot coolant..)..does not even remotely smell like coolant...maybe a little electrical..but could it be freon from the air conditioning...or an air bag canister leaking off....the thing is it was single digit temperature the night before and wonder if something started to leak..to gas into the cabin...I opened the doors and aired out but seems to build back up then enclosed...???.looked under dash at wiring..everything seems to work...any thoughts???? not ruling out electrical...kinda smells electrical but at the same time not sure?? does that make sense?

[12Ounce]

It won't be "freon" ... that stuff is allowed no more, but it might well be refrigerant and the oil included. Try the ac, if its warm enough where you are, .... and see in the clutch stays engaged. If so, you can discount refrigerate leak.

There are a number of electrical items in the cabin that may be biting the dust ... air pumps for lumbar, seat adjustment motors, window regulators, ... etc, etc. And the "stinker" may be in the engine bay ....and coming thru the air intake.

[tempfixit]

Could it be battery acid you smell? Have you looked at the battery?

[schadd1971]

new battery..about a month ago....this is weird...It doesn't smell like engine compartment /exhaust fumes...kinda has that ozone like smell...am leaning towards A/C but not sure..I will check the compressor cycle...other than that runs great and the van is in really good shape and taken care of pretty well..I checked everything ( all the electrical accessories all seems to work....still puzzled...

[tempfixit]

Have you checked the alternater output with a voltmeter?? Could it be possible that the alternater regulator is stuck on a high output causing the battery to boil causing the smell.

[schadd1971]

I will check that too...all good suggestions you never think off..I have gotten alot of good ideas in the past from you guys....better stuff than from talking to local mechanics...

[catvents]

It is sometime difficult to identify the nature of the odor, which could be from chemical or electric issue. Do you want to try the following: look under the passenger side dash, you will find on the heater box a connector (with a few wires), connected to the blower motor resistor. Take a look on the condition of the connector if it is not melted (or almost) In case you don't know this resistor control (or reduce) the speed of the blower motor and is in use when you set the fan speed to medium or low. As the blower motor is using a lot of current, after many years of use, oxydation can have build up on the connector terminal, causing the terminal to overheath enough to make the plastic connector to melt. This is what happened to mine a few years ago, and it was a real burnt odor that I was smelling in the van. If it is the situation, you will have to replace the connector ( or temporary use your fan blower speed at the max setting only, until it is replaced. Current does not have to flow through the resistor at the maximum speed setting. Let us know.

[schadd1971]

will check that too...the bad thing is I want to get on this but its cold and snowy and my wife who normally doesnt work weekends has the van for two long days...bad timing for trying to find a problem...but when does a problem have good timing....the smell she says is still there..not as bad as first but still present after two days...will let you know what I find...