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The root cause is a bad weld on the upstream side of the catalyst causing an exhaust leak. The fix is to replace the catalytic converter, which is what Toyota eventually did for my truck.

I paid about 50 bucks for the smoke tester on Amazon. Any auto shop should be able to do this test for you in an hour or less.

Sounds like the conditions when I noticed it most: cold start, climbing a hill, coming to a stop on a freeway offramp. Always with HVAC on fresh air, no heat or AC.

For anyone else dealing with this issue, I diagnosed the problem and got Toyota to resolve it. Please see this post: https://www.tacoma4g.com/forum/threads/burning-smell-in-cabin.9376/post-257972

I finally got Toyota to acknowledge and repair this issue in May 2026. The first time I brought my truck in for this was in July 2025. The problem with my truck was an exhaust leak from a weld joint on the upstream side of the catalytic converter, less than 18 inches from the cabin vent intake...

What's an exhaust dump?

Interesting, I'm at 9,500 miles and still experiencing the smell every time I drive the truck.

Posting this poll because I'm curious how many other owners have noticed a burning / exhaust smell through the dash vents in their Tacomas? The smell is also observable underhood on the passenger side of the engine compartment. Specific conditions when the smell is most noticeable: Dash vents...

Has anyone succeeded in getting Toyota to acknowledge and repair this issue? My truck does it and Toyota is still not acknowledging the problem even after many dealer visits, inspection by a Toyota Field Technical Specialist, written request to Toyota corporate seeking repair, and lemon law...