2004 Mercedes-Benz E-Class Fuel System

NHTSA ACTION NUMBER: PE12001 BEGAN SMELLING FUEL COMING FROM REAR DRIVER'S SIDE AREA (UNDER REAR SEAT) ONCE FUEL TANK WAS FULLY FILLED UP. THE SMELL WOULD PERSIST UNTIL A LITTLE ABOVE 3/4'S OF THE TANK REMAINING. ABOUT TWO MONTHS LATER, WHEN TRYING TO FILL TANK UP ALL THE WAY, GAS PUMP WOULD CLICK OFF BEFORE FILLING UP (WITH ABOUT 2 OR 3 GALLONS STILL EMPTY IN THE TANK). BEGINNING OF MARCH, THE CHECK FUEL CAP WARNING WOULD COME ON IN THE INSTRUMENT CLUSTER. FUEL CAP WAS REPLACED AND STILL SAME ERROR SHOWS. *TR

CONSTANT FUEL LEAK, WITH FUEL VAPORS THAT CAN BE SMELLED OUTSIDE AND INSIDE OF THE CAR. THE LEAK IS WORSE AFTER FUELING THE CAR. THERE IS A CONSTANT FUEL SMELL INSIDE THE CAR. *JS

GAS ODOR BOTH INSIDE AND OUTSIDE OF VEHICLE WHEN TANK IS FILLED TO MAXIMUM CAPACITY. ODOR LINGERS UNTIL TANK IS ABOUT HALF EMPTY. INSPECTED FUEL PUMP/FILTER LOCATED UNDER REAR DRIVERS SIDE SEAT AND DISCOVERED GAS LEAKAGE/PUDDLE. GAS LEAK IS WITHIN A COUPLE OF CENTIMETERS FROM TWO ELECTRICAL CABLE CONNECTIONS ATTACHED TO FUEL PUMP/FILTER - AN IMMINENT FIRE HAZARD. PREVAILING FUMES ARE HAZARDOUS TO VEHICLE PASSENGERS, ESPECIALLY SMALL CHILDREN, AND MAY CAUSE DIZZINESS WHILE DRIVING OR LOSS OF CONSCIOUSNESS. *TR

FUEL SENDER UNIT LEAKED INTO THE TOP OF THE PUMP AREA CAUSING A SMELL OF GASOLINE IN THE CAR. SENDER UNIT WAS REPAIRED BUT SMELL REMAINED. SENDER AND PUMP UNIT WERE REPLACED AND AFTER 14 MONTHS THE SMELL OF GASOLINE IS BACK ALONG WITH POOLING ON THE TOP OF THE PUMP AREA. WHEN FILLING THE CAR AT THE GAS STATION THERE IS SOMETIMES A SMALL PUDDLE OF GAS UNDER THE REAR FILLER AREA WHEN DONE. *TR

MY 2004 E55 AMG WAS PARKED IN THE GARAGE AFTER DRIVING HOME FROM WORK. WHEN RETURNING TO THE GARAGE ABOUT 45 MINUTES LATER I IMMEDIATELY NOTICED THE GARAGE WAS CONSUMED WITH GAS FUMES. I BACKED THE CAR OUT OF THE GARAGE ONLY TO FIND THAT A 1/4 TANK OR SO OF GAS HAD SPILLED ON THE FLOOR. HESITANT TO LEAVE THE CAR IN THE GARAGE OVERNIGHT, I DROVE THE CAR 10 MINUTES DOWN THE ROAD TO MY LOCAL MERCEDES-BENZ DEALER FOR INSPECTION. (I THOUGHT IT BEST NOT TO WAIT UNTIL MORNING, AS HOT EXHAUST PIPE AND GAS SPILL WAS NOT SOMETHING I AM COMFORTABLE WITH.) I FOUND THAT MANY VEHICLES HAVE EXPERIENCED THIS ISSUE AND THIS IS NOT UNCOMMON OF MY MAKE AND MODEL VEHICLE. AFTER READING MANY SAFETY CONCERNS AND EVEN HAVING MY OWN CONCERNS NOW OF DRIVING THE CAR, I DECIDED TO WRITE THIS FORMAL COMPLAINT. EVEN AFTER THE REPAIR, THE CAR SMELLS OF GASOLINE INSIDE AND OUTSIDE. STILL HESITANT TO PARK IN THE GARAGE, I AM KEEPING THE CAR OUTSIDE UNTIL IT HAS BEEN DETERMINED SAFE. *TR

I HAVE A 2004 MERCEDES AMG E55. I PURCHASED THE CAR SECOND HAND FROM MY NEIGHBOR AT +/-33,000 MILES. ONE WEEK OF OWNERSHIP, I GOT A CHECK ENGINE LIGHT. I HAD ACCESS TO A OBD2 SCANNER AND GOT THE CODE FOR EVAP ERROR. I STORED THE CAR OVERNIGHT IN MY GARAGE AND WOKE UP THE FOLLOWING MORNING WHERE THE WHOLE HOUSE REEKED OF FUEL. I HAD RECENTLY FILLED UP THE NIGHT BEFORE. BEING FAMILIAR WITH THIS MERCEDES VEHICLE I WENT OVER THE FUEL SYSTEM FROM GAS SPOUT TO GAS TANK. THE SMELL WAS COMING FROM INSIDE THE CAR UNDER THE REAR DRIVERS SIDE PASSENGER SEAT. UPON FURTHER INSPECTION AND REMOVAL OF THE SEAT,ACCESS PANEL. I COULD SEE GASOLINE PUDDLING UP ON TOP OF THE FUEL SENDER. I GOT SOME PAPER TOWELS AND DRIED IT. THAT MORNING I BOUGHT A NEW GASKET SEAL FROM THE DEALER TO TRY AND ISOLATE THE PROBLEM. THAT DID NOT HELP...NEXT GAS FILL UP THE CAR CONTINUE TO SMELL LIKE FUEL INSIDE THE CABIN. I TOOK IT TO A INDEPENDENT MECHANIC WHO PERFORMED THE SMOKE TEST TO SEE WHERE THE LEAK IS COMING FROM AND SURE ENOUGH IT WAS FROM THE TOP OF THE GAS TANK WHERE IT MET THE FUEL SENDER. UPON TAKING THE CAR TO THE DEALER, I'VE BEEN TOLD I HAVE TO REPLACE THE ENTIRE GAS TANK, FUEL PUMP, FUEL SENDER AND FITTINGS TO FIX THIS PROBLEM. THE DEALER WANTS ME TO PAY OUT OF POCKET THE ENTIRE COST WHICH IS ABOUT $3,000. THERE STILL IS A EMISSIONS WARRANTY ON THE CAR WHICH IS GOOD UP TO 8 YEARS OR 80,000 MILES WHICH THEY WILL NOT HONOR AS THEY FEEL THIS ISSUE DOESN'T QUALIFY. THEY HAVE JUST LAUGHED AT THE SITUATION AND TRIED TO DOWNPLAY IT. A LOT OF CUSTOMERS HAVE BEEN FORCED TO PAY OUT OF POCKET TO COVER THIS REPAIR AS THEY TRANSPORT THEIR KIDS IN THIS CAR AND THAT IS VERY IMPORTANT. TO PREVENT ANY FURTHER LEAKING, I ONLY FILL MY CAR WITH GAS HALFWAY AND HAVE RESET THE CHECK ENGINE LIGHT WITH MY SCANNER. THANK YOU. *TR

FUEL TANK LEAKS FUEL ONTO THE GROUND VIA THE EXTERNAL INTER TANK TRANSFER HOSE ON THE TOP OF THE TANK. TO REPAIR THIS MERCEDES HAS TO REPLACE THE TANK WHICH REQUIRES A COMPLETE TEARDOWN OF THE REAR SUSPENSION AND REAR SUBFRAME. I BROUGHT THE CAR TO THE DEALER FOR THIS ISSUE 5 TIMES, ANY TIME THE TANK WAS GREATER THAN HALF FULL IT WOULD LEAK A SIGNIFICANT (A PUDDLE FORMED) AMOUNT OF FUEL ON THE GROUND. MERCEDES BENZ DID NOT WARRANTY THIS ISSUE STATING THAT THEY HAVE NEVER SEEN THIS ISSUE AND IT WAS A ONE TIME THING, EVEN THOUGH THEY "REPAIRED" IT FIVE TIMES. *TR

STARTED SMELLING GAS AFTER FILLING UP AND EVENTUALLY FOUND THAT THE FUEL SENDER/HOSE WAS SPRAYING FUEL ON THE UNDERSIDE OF THE CAR/REAR SEAT. AFTER RESEARCHING THE PROBLEM I FOUND THAT FUEL LEAKS COMING FROM AND AROUND THE TANK ARE VERY COMMON AND THAT THERE WAS A RECALL YEARS AGO TO REINFORCE THE SENDER/HOSE. FUEL WAS ALSO LEAKING AND PUDDLING UP AROUND THE FUEL PUMP AND THE FUEL SENDER. THIS IS OBVIOUSLY A DESIGN/PART FLAW AND NEEDS TO BE ADDRESSED AS IT HAPPENS REPEATEDLY TO MANY PEOPLE. *TR

FUEL SENDING UNIT IS LEAKING, THERE IS A HEAVY FUEL SMELL INSIDE THE CAR. *TR

WHEN YOU FILLED THE TANK UP AT ANY TIME, THERE WOULD BE A HORRENDOUS RAW FUEL SMELL UNTIL THE FUEL LEVEL DROPPED OFF OF FULL. IT WAS SO BAD I HAD TO PARK THE CAR OUTSIDE INSTEAD OF IN THE GARAGE FOR FEAR OF A FIRE STARTING AND A SUBSEQUENT EXPLOSION. I TOOK IT TO THE DEALER AND I HAD AN EXTENDED WARRANTY. THE DEDUCTIBLE WAS $200. THEY ENDED UP HAVING TO REPLACE THE ENTIRE FUEL TANK, FUEL PUMP AND ALL RELATED ITEMS TO AN UPDATED MODEL TO GET RID OF THE PROBLEM. I AM STILL OUT THE $200 DEDUCTIBLE FOR MY EXTENDED WARRANTY. *TR

TL* THE CONTACT OWNS A 2004 MERCEDES BENZ E320. THE CONTACT STATED THAT THE VEHICLE WAS PARKED AND SHE SMELLED A STRONG ODOR OF FUEL. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER AND THE FUEL PUMP WAS REPLACED. THE FAILURE CONTINUED. THE VEHICLE WAS TAKEN BACK TO THE DEALER AND THE SEAL RING ON THE FUEL PUMP WAS REPLACED. THE FAILURE CONTINUED. THE VEHICLE WAS AGAIN TAKEN BACK TO THE DEALER AND THE CONTACT WAS INFORMED THAT THE FUEL TANK WAS LEAKING. THE CONTACT WAS ALSO INFORMED THAT THE ENTIRE FUEL TANK MAY NEED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE FAILURE MILEAGE WAS 107,830.

FUEL SYSTEM LEAKS AT SENDING UNIT/PUMP AFTER FUELING UP VEHICLE. FUEL SITS ON TOP OF SENDING UNIT/PUMP UNTIL FUEL TANK REACHES APPROX 3/4 OF A TANK. VEHICLE HAD CAMPAIGN(RECALL) FOR FUEL SENDER CONDUCTED IN 2008 ACCORDING TO DEALER AND MB USA. HAVE CONTACTED BOTH ABOUT THE ISSUE AND NEITHER SAY THEY'VE HEARD OF A PROBLEM. DEALER SAID THEY WOULD LOOK INTO IT BUT WOULD CHARGE A DIAGNOSTIC FEE. HAVE PICTURES OF FUEL ON OF SENDING UNIT/PUMP ALSO. AFTER FUELING VEHICLE THE VEHICLE CAN NOT BE STORED IN MY GARAGE DUE TO THE VAPOR FUMES FILLING MY GARAGE AND ALSO MY HOUSE. AFTER FUELING A STRONG SMELL OF GARAGE CAN BE SMELT OUTSIDE OF THE VEHICLE AND IN THE SUMMER MONTHS SMELT INSIDE THE VEHICLE AT TIMES. *TR

I CURRENTLY DRIVE A 2004 MERCEDES E500 4MATIC WITH 78,000 MILES CURRENTLY ON IT. RECENTLY, AFTER REFUELING THE CAR I HAVE NOTICED A VERY STRONG ODOR OF GASOLINE BOTH INSIDE AND OUTSIDE OF THE CAR. AFTER HAVING THE SAME ISSUE AFTER FILLING MY TANK ABOUT 3 TIMES I DECIDED TO DO SOME RESEARCH ON THE ISSUE. WITH NOT MUCH SEARCHING I FOUND A FLOOD OF COMPLAINTS FROM MERCEDES OWNERS CLAIMING THE EXACT SAME ISSUES. FROM WHAT I HAVE GATHERED IT SOUNDS LIKE ITS A SAFETY CONCERN AND IS A DESIGN FLAW. *TR

TL*THE CONTACT OWNS A 2004 MERCEDES BENZ E320. THE CONTACT STATED THE VEHICLE WAS BEING EXAMINED BY AN AUTHORIZED DEALER FOR ROUTINE MAINTENANCE WHEN HE WAS INFORMED THERE WAS A FUEL LEAK COMING FROM THE FUEL SENDING UNIT. THE CONTACT WAS ALSO INFORMED THERE WAS A FAILURE WITHIN THE SEAL OF THE FUEL SENDING UNIT. THE MANUFACTURER WAS NOT AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE FAILURE AND CURRENT MILEAGES WERE 102,000.

FUEL SENDING UNITS CRACKED ON DRIVERS SIDE CAUSING GAS TO POOL ON TOP OF SENDERS....LITERALLY SIX INCHES FROM WHERE MY THREE YEAR OLD SITS IN THE CAR. FUEL IS POOLING ON TOP OF SENDER UNITS AND THEN DRAINING DOWN GAS TANK AND OUTSIDE THE VEHICLE. IN ADDITION, THE ENTIRE CABIN OF VEHICLE INSIDE AND OUT SMELLS OF FUEL. *TR

BOTH FUEL SENDING UNITS LEAKING FROM THE TOP OF THE FUEL TANK. FUEL WAS PUDDLING UNDER THE REAR SEATS AND WAS DRIPPING ON TO THE GROUND. BOTH SENDING UNITS WERE REPLACED AT OUR EXPENSE. OTHER OWNERS OF THE SAME VEHICLE ARE HAVING THE SAME ISSUES AND MERCEDES IS NOT COOPERATING WITH STARTING A RECALL PROCESS. THIS ISSUE IS A SAFETY CONCERN AS WELL AS AN ENVIRONMENTAL ISSUE. *TR

2004 MERCEDES BENZ E320. CONSUMER STATES PROBLEM WITH VEHICLE GAS TANK *TGW THE CONSUMER STATED AFTER REFUELING THE VEHICLE, HE SMELLED A STRONG ODOR OF GAS IN THE DAYS THAT FOLLOWED. THE VEHICLE WAS TAKEN TO AN AUTHORIZED SERVICE CENTER WHERE AN INSPECTION REVEALED THE FUMES WERE COMING FROM A HOLE IN THE GAS TANK, WHICH WAS A WELL- KNOWN MANUFACTURING DEFECT. *JB

2004 E320 MERCEDES FUEL SMELL POSSIBLY DUE TO A RECALL ISSUE OF THE FUEL SENDER RECALL AND/OR FUEL FILLER RECALL . I JUST PURCHASED THE CAR A COUPLE OF MONTHS AGO AND NOTICED THIS SMELL YESTERDAY WHEN I FILLED UP MY GAS TANK. I DID SOME RESEARCH AND NOTICED THAT THERE WAS AN EMISSIONS RECALL FROM MERCEDES ABOUT THESE ISSUES. I AM SCARED THAT THE RECALL PART IS LEAKING FUEL AND WILL BLOW UP KILLING MY FAMILY AND I. *TR

FUEL TANK LEAK. GARAGE IS FILLED WITH GAS SMELL. AFTER READING ON LINE, IT SEEMS THAT THOUSANDS OF OTHER MB E-CLASS (MODEL YEAR 03 - 06) ARE HAVING THE SAME EXACT ISSUE. THIS IS A CLEAR SAFETY HAZARD AND IN THE HOT AND HUMID VIRGINIA WEATHER, THE CAR IS A MOBILE BOMB WAITING TO GO OFF. PLEASE FORWARD THIS TO THE ENGINEER THAT IS WORKING/LOOKING AT THE EXISTING COMPLAINTS FOR THE SAME ISSUE. *TR

2004 MERCEDES E55 AMG LEAKING FUEL AFTER EVERY FILL. VERY STRONG FUEL SMELL INSIDE THE VEHICLE AFTER FILLING UP (STOPPED FILL BEFORE CLICK). REPAIRED PASSENGER SIDE FUEL SENDING UNIT UNDER BACK SEAT AT MB SERVICE BUT ISSUE IS STILL OCCURRING AFTER REPAIR. DURING A 6 OR 7 MONTH PERIOD, MERCEDES HAS TRIED TO FIX ON 5 OCCASIONS WITHOUT SUCCESS. THEY REPLACED ALL KINDS OF SENSORS IN THE ENGINE DEPT AND HAD THE CAR FOR OVER A MONTH BUT THE ISSUE WAS WITH THE FUEL RELATED PARTS. THEY MISS DIAGNOSED THE PROBLEM FOR THE FIRST 6 MONTHS. FINALLY MB DIAGNOSED THE ISSUE LATE 2010 AND REPLACED ONE OF THE SENDING UNITS, THE SENDING UNITS WERE ALSO REPLACED UNDER RECALL FOR THIS VEHICLE IN JULY 2008. MB STATED THE CAR WAS NOW REPAIRED BUT AFTER LEAVING THE DEALERSHIP THE CHECK ENGINE LIGHT CAME ON AGAIN. THE CAR HAS NOW FAILED AIR CARE, AN ADDITIONAL EXPENSE. ALL ISSUES RELATE TO FUEL TANK, EVAP VALVE AND DEFECTIVE FUEL SENDING UNITS. HESITATION, CHECK ENGINE LIGHT, ROUGH ENGINE OPERATION FUEL LEAKS AND SMELL. THIS IS CLEARLY A SAFETY ISSUE, FUEL VAPORS ARE COMBUSTIBLE. NOW MERCEDES HAS WASHED THEIR HANDS OF THE ISSUE AND WE (CONSUMERS AND OWNERS OF E55 AMG'S) ARE LEFT TO REPAIR THE PROBLEM AT OUR EXPENSE. THE RECALL CAMPAIGN #2008-020001 IN 2008 HAS RESULTED IN REPEATED FAILURES OF THE SENDING UNITS HOWEVER MERCEDES BENZ IS NOT TAKING RESPONSIBILITY. THERE ARE OVER 40 OWNERS OF THESE VEHICLES ON LINE WITH EXACTLY THE SAME ISSUES. MB USA NEEDS TO ACCEPT RESPONSIBILITY AND RECALL THESE VEHICLES FOR A FUEL CELL SAFETY ISSUE. THERE IS A POTENTIAL FOR COMBUSTIBLE FUEL VAPORS AND I PRAY IT DOES NOT HAPPEN BEFORE MB USA TAKES RESPONSIBILITY. ALTHOUGH THE NUMBER OF OWNERS ARE ONLY APPROXIMATELY 40 AT THIS POINT, THERE MAY BE MANY MORE OUT THERE WITH THE E-CLASS MB FUEL LEAK ISSUE. MB USA NEEDS TO OWN UP TO THE PROBLEM. *TR

A STRONG ODOR OF GASOLINE EMANATES FROM CAR AFTER FILLING IT UP WITH GASOLINE. HAD A MECHANIC TROUBLE SHOOT AND IT WAS DETERMINED TO BE A LEAK IN THE FUEL SENSOR WHICH WAS CAUSING GASOLINE TO PUDDLE ON TOP OF FUEL TANK UNDERNEATH THE BACK SEAT OF THE AUTOMOBILE. *KB

TL* THE CONTACT OWNS A 2004 MERCEDES BENZ E 320. THE CONTACT STATED THAT THE VEHICLE WAS PARKED IN THE GARAGE AND EXHIBITING AN ABNORMALLY OVERPOWERING GASOLINE FUEL ODOR. THE ODOR FILLED BOTH THE GARAGE AND THE CONTACTS RESIDENCE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC WHO DIAGNOSED THE FAILURE AS A FUEL LEAK. THE MANUFACTURER WAS CONTACTED AND ADVISED THAT A CASE MANAGER WOULD RETURN THE CONTACTS CALL. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 22,716. UPDATED 08/01/11*LJ UPDATED 08/03/11 UPDATED 2/29/12 *CN

MERCEDES 2004 E320 FUEL TANK LEAKING UNDER REAR PASSENGER SEAT. STRONG ODOR OF GASOLINE WHICH IS WORST RIGHT AFTER FILLUP, BECAME PROGRESSIVELY WORSE OVER TIME. *TR

I HAD A MERCEDES BENZ E-CLASS RECALL TO REPLACE THE FUEL SENDING UNIT DONE IN 2008 AND A YEAR AND A HALF LATER I STARTED SMELLING GAS INSIDE MY CAR EACH TIME I FILLED UP THE TANK. I IGNORED IT IN THE BEGINNING BUT AFTER A WHILE I GOT THE CHECK ENGINE LIGHT ON. I WAS SURE IT WAS RELATED TO THE GAS SMELL SO I TOOK MY CAR TO THE DEALER FOR INSPECTION, AND THEY SAID THE FUEL SENDING UNIT NEEDED TO BE REPLACED COMPLETELY FOR A COST OF $1200 PLUS LABOR (UNFORTUNATELY I DID NOT BUY THE EXTENDED WARRANTY). I KNOW A CAR MECHANIC IN MY NEIGHBORHOOD WHO DEALS WITH QUITE A LOT OF HIGH END CARS AND CHARGES LESS THAN A THIRD OF WHAT THE DEALER DOES, SO RIGHT AWAY I PICKED UP MY CAR, BOUGHT AN O-RING FOR THE FUEL SENDING UNIT FROM THE DEALER'S PARTS STORE (THANKS TO THE RESEARCH I DID IN A MERCEDES FORUM), AND HAD IT REPLACED BY THE LOCAL MECHANIC I KNOW FOR $50. EVER SINCE, NO MORE LEAKS FOR NOW, BUT I DO THINK THIS IS A TEMPORARY SOLUTION AND IT MAY START LEAKING AGAIN AFTER THE SENDING UNIT'S FUEL CAP OR ITS O-RING STARTS MELTING AGAIN FROM OVERHEATING LIKE SOME OTHER MEMBERS IN THE FORUM MENTIONED. THIS MUST BE A DESIGN FLAW WITH THE CAR AND DEFINITELY NEEDS TO BE TAKEN SERIOUSLY BEFORE SOMEONE ENDS UP LOOSING HIS/HER LIFE. *TR

TAPPING NOISE INSIDE THE CAR : THE FUEL CANISTER TOUCHES THE CHASIS AND MAKE LOUD TAPPING NOISE INSIDE THE CAR, REPORTED THIS TO MBUSA AND REPERESETATIVE PUT INSULATION AROUND FUEL CANISTER AND WHICH IS NOT SAFE. *JB