2003 Mercedes-Benz E-Class Fuel System

I COULD SMELL FUEL LEAKS OR A STRONG ODOR OF GASOLINE BOTH INSIDE AND OUTSIDE OF THEIR VEHICLE, AND AFTER REFUELING. WENT TO MB DEALERSHIP FOR TUNE UP, OIL, AND AIR FILTER CHANGE. TWO DAYS LATER THE VEHICLE STALLED ON ME DRIVING DOWN 55 SOUTHBOUND INTERSTATE AT 65MPH. I WAS IN DENSE TRAFFIC SO I TURNED ON MY EMERGENCY FLASHERS AND TRIED TO COAST THE CAR ONTO THE SHOULDER TO GET SAFELY OFF THE ROAD. SCARY SINCE TRAFFIC WAS SO DENSE BUT I MANAGED. I TRIED TO START THE CAR A FEW TIMES AND IT WOULDN'T START. AFTER 5 MINUTES IT STARTED AND I DROVE TO MY DESTINATION 2 MILES. AFTER SITTING FOR 30 MINUTES I HEADED BACK HOME 55 NORTH BOUND AT 65MPH. CONCERNED I DROVE IN THE FAR RIGHT LANE IN CASE THE VEHICLE STALLED AGAIN. IT STALLED 5 TIMES TRAVELING 25 MILES. ONCE I ARRIVED HOME THE VEHICLE REEKED OF FUEL. CALLED THE MERCEDES DEALERSHIP AND ASK IF THIS WAS A PART OF THE RECALL (CAMPAIGN NO. 2008020001) OF THE FUEL FILTER MODULE? WAS TOLD NO. I DROVE THE CAR HOPING IT WAS JUST BAD GAS OR SOMETHING AND IT STALLED AT A STOP LIGHT AND IT WAS 5+ MINUTES BEFORE IT STARTED AGAIN. I DROVE INTO THE FIRST ASE SHOP 1/2 MILES UP THE ROAD. THE SHOP CHECKED THE VEHICLE AND DETERMINED THAT THE FUEL FILTER MODULE WAS BAD AND MUST BE REPLACED. THE PART WAS ORDERED FROM THE MB DEALERSHIP AND INSTALLED. IN ADDITION A NEW FUEL PUMP WAS INSTALLED AS WELL. UPON REMOVING THE SEAT THE TECH DISCOVERED FUEL UNDER THE SEAT AND THE MATTING SOAKED. HE STATED I WAS LUCKY THE VEHICLE DID NOT CATCH ON FIRE. MB INDICATES MY MODULE WAS REPLACED IN 2008 PER THE RECALL. FIVE YEARS AND THE VEHICLE IS STILL NOT SAFE. MB REFUSES TO REIMBURSE ME FOR THE COST OF REPLACING THE MODULE. *TR

TL* THE CONTACT OWNS A 2003 MERCEDES BENZ E500. THE CONTACT STATED THAT WHEN HE REFUELED, HE COULD SMELL STRONG GASOLINE FUMES INSIDE AND OUTSIDE THE VEHICLE. THE VEHICLE WAS TAKEN TO A DEALER FOR DIAGNOSIS AND THE CONTACT WAS INFORMED THAT THERE WAS A LEAK ON TOP OF THE FUEL TANK AND THE TANK WOULD NEED TO BE REPLACED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE AND DID NOT OFFER ANY ASSISTANCE. THE VEHICLE WAS REPAIRED. THE FAILURE AND CURRENT MILEAGE WAS 113,000. UPDATED 09/17/13*LJ THE CONSUMER STATED THE DEALER OFFERED A 15% DISCOUNT. UPDATED 09/20/2013 *JS

THERE WAS GASOLINE LEAKING FROM THE TOP OF THE FUEL SENDING UNIT, AROUND THE FUEL SENDING UNIT, UNDER THE REAR PASSENGER SEAT AND ACTUAL LIQUID FUEL WAS GOING INTO THE CABIN OF THE VEHICLE. THE STRONG AND INTENSE FUMES AND VAPORS ARE INSIDE THE CABIN AND APPARENT AFTER FILLING THE FUEL TANK ONLY HALF TO THREE-QUARTERS FULL. BOTH OF THESE POSE AN EXTREME DANGER OF FIRE HAZARD, AS WELL AS A HEALTH RISK FROM CONSTANTLY INHALING GASOLINE FUMES. THIS ALLOWED FUMES TO LEAK INTO MY GARAGE AND PRESENTED A HUGE FIRE RISK HAD I NOT DISCOVERED THE PROBLEM. A GAS TANK SHOULD NOT FAIL UNDER NORMAL WEAR AND TEAR, BUT IN OCTOBER 2012 I PAID OVER $1,600 FOR A NEW FUEL TANK, IN APRIL 2013 I PAID OVER $1,200 FOR A NEW FUEL PUMP AND IN AUGUST 2013 I PAID OVER $700 FOR ANOTHER NEW FUEL PUMP. THIS IS A RECURRING PROBLEM AND THE COMPANY DOES NOT SEEM INTERESTED IN TAKING ANY ACTION WHATSOEVER. I BELIEVE THIS IS A HUGE SAFETY CONCERN AND I HOPE SOMETHING CAN BE DONE TO RECTIFY AND REMEDY THIS SITUATION. CONSUMERS DESERVE BETTER THAN THIS. UPDATE09/17/13*LJ UPDATED 09/24/2013 *JS *TR

ON SEPTEMBER 1ST 2013 I WENT TO LEAVE MY HOUSE. SMELT A STRONG GAS SMELL, THOUGHT POSSIBLY SOMEONE HAD SPILT A GAS TANK. START LOOKING AROUND FOR GAS COULDN'T FIND ANY AROUND MY HOUSE SO I GET IN MY CAR WHEN I DO I GET A STRONG SCENT OF GAS. I TAKE MY BACK SEAT OUT REMOVE THE COVER ON THE FUEL PUMP ON MY DRIVERS SIDE AND THEIR IT WAS A HUGE PUDDLE OF GAS IN MY BACK SEAT. AT THAT POINT I CALLED A TOW TRUCK AFRAID TO DRIVE THE VEHICLE AFRAID IT MAY CATCH ON FIRE. I TAKE IT TO THE LOCAL MERCEDES DEALER THEY HAVE TO REPLACE MY DRIVERS SIDE FUEL SENDING UNIT, AND COME TO FIND OUT MY PASSENGER SIDE FUEL SENDING UNIT HAS BURNED UP ALSO. UPDATED 09-18-13 *BF UPDATED 09/25/2013 *JS

FUEL SENDER LEAK, GARAGE SMELLS LIKE GAS. PLEASE MAKE MERCEDES FIX THIS. CAR IS A TICKING TIME BOMB, ESPECIALLY WITH THIS HORRIBLE HEAT IN AZ. *TR

STRONG GASOLINE SMELL AFTER FILLING. THE SMELL LASTS AT LEAST 2-3 DAYS BEFORE DISSIPATING AND HAPPENS EVERY TIME WE FILL IT. PROBLEM WAS REPORTED TO THE DEALER MULTIPLE TIMES. *TR

VEHICLE IS PARKED, STRONG GASOLINE SMELL INSIDE AND OUTSIDE OF VEHICLE. ESPECIALLY IF THE GAS TANK IS AT LEAST 3/4 QUARTER FILLED. *TR

TL* THE CONTACT OWNS A 2003 MERCEDES BENZ E500. THE CONTACT STATED THAT WHILE PARKED, THERE WAS A STRONG FUEL ODOR AROUND THE VEHICLE. THE VEHICLE WAS NOT TAKEN TO THE DEALER FOR A DIAGNOSIS. THE MANUFACTURER WAS NOT MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE AND CURRENT MILEAGE WAS 100,000. *TR ...UPDATED 07-29-13 *BF THE CONSUMER STATED THE FUEL LEAK WAS LOCATED RIGHT UNDER THE REAR PASSENGER SEAT ON THE DRIVER'S SIDE. THE DEALER REPLACED THE FUEL SENDER UNIT.

TL* THE CONTACT OWNS A 2003 MERCEDES E55. THE CONTACT STATED HE NOTICED A STRONG GASOLINE ODOR INSIDE THE VEHICLE. THE VEHICLE WAS TAKEN TO THE DEALER FOR DIAGNOSIS WHERE THE CONTACT WAS ADVISED THAT THE FUEL PUMP WAS FRACTURED AND WOULD HAVE TO BE REPLACED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 47,000. *TR

MY WIFE WAS DRIVING HOME FROM WORK WHEN SHE SMELLED A NOXIOUS GASOLINE ODOR. TOOK CAR FOR REPAIRS ON AUG 23, 2013. HAD TO REPLACE THE AUXILIARY (SENDING) PUMP AND THE CABLE HARNESS ATTACHED TO THE FUEL TANK. MERCEDES HAS HAD NUMEROUS ISSUES WITH THE FUEL TANK AND PUMP BUT THEY REFUSE TO DO A RECALL AND FIX THE PROBLEM. THIS REPAIR COST $664.18 TO FIX ITEMS THAT ARE INHERENTLY DEFECTIVE IN THE MERCEDES VEHICLES. *JB

AFTER FILLING THE GAS TANK THERE WAS A STRONG SMELL OF GASOLINE AND LEAKING FUEL NEAR THE DRIVERS SIDE REAR TIRE. UPON CALLING A MECHANIC THEY SAID TO LOOK UNDER THE SEAT FOR LEAKING FUEL. THE FUEL SENDING UNIT WAS DEFINITIVELY LEAKING. *TR

FUEL LEAKING FROM VEHICLE NEAR REAR LEFT TIRE. FOUND FUEL AROUND FUEL SENSOR UNDER REAR PASSENGER SEAT. MOST EVIDENT AFTER FILLING FUEL TANK. FIRST DISCOVERED LEAK AT 70K MILEAGE AND AGAIN ON 128K. *TR

EVERY TIME I FILL MY VEHICLE UP WITH FUEL, THERE IS AN OVERPOWERING ODOR OF GASOLINE BOTH OUTSIDE OF THE CAR, AND INSIDE THE CABIN. THE SMELL IS STRONG ENOUGH TO CAUSE A HEADACHE IN SHORT ORDER. WHEN REMOVING THE BACK SEAT OF THE VEHICLE, YOU CAN OBSERVE STANDING FUEL ON THE FUEL SENDER ASSEMBLY. I'M UNSURE IF THIS PROPAGATES FROM THE SPOT OF THE BUILD UP, OR IS FROM ANOTHER PLACE AND THIS IS WHERE IT ULTIMATELY ENDS UP. A LARGE CONCERN FOR ME, BESIDES THE EXPOSURE TO GASOLINE FUMES, IS THE PROXIMITY TO THE FUEL BUILD UP TO ELECTRICAL WIRING, WHICH I BELIEVE WOULD CONSTITUTE A FIRE HAZARD. I PREVIOUSLY HAD A VOLUNTARY RECALL DONE ON MY CAR IN 2008 THAT HAD TO DO WITH THE FUEL SYSTEM, BUT I'M NOT CONVINCED THAT ACTUALLY FIXED THE ROOT CAUSE OF THIS ISSUE. *TR

IN REFERENCE TO NHTSA CAMPAIGN ID NUMBER: PE12001 VEHICLE WAS TAKEN IN FOR SERVICING UNDER (EMISSIONS RECALL CAMPAIGN # 2008-020001) AND FUEL SENDER UNIT WAS REPLACED. THIS CORRECTED THE PROBLEM FOR APPROXIMATELY TWO YEARS AT WHICH POINT THE SMELL OF FUEL INSIDE THE VEHICLE RETURNED AND THERE ARE NOTICEABLE LEAKS ON BOTH THE FUEL SENDER AND FUEL PUMP. THE VEHICLE WAS TAKEN IN TO HAVE THE DEALER SERVICE THE PART UNDER THE RECALL AS THE REPLACEMENT PARTS WERE FAULTY AS THEY WERE NO DIFFERENT THEN THE PARTS THEY REPLACED. THEY ALSO NOTED THAT THE PUMP MAY BE CRACKED. *TR

FUEL PUMP AND ASSEMBLY WERE LEAKING FUEL INTO CABIN AREA DUE TO FAULTY DESIGN AND PLASTIC PARTS. *TR

SENDING UNIT LEAKS GASOLINE INTO THE CABIN OF THE VEHICLE LETTING IN INTENSE FUEL VAPORS AS WELL AS ACTUAL LIQUID FUEL INTO THE CABIN. FURTHERMORE THE FAULTY SENDING UNIT CAUSES A FUEL LEAK FROM THE GAS TANK TO THE EXTERIOR OF THE VEHICLE LEAVING PUDDLES OUTSIDE OF THE CAR WHILE PARKED AND CONTINUING TO LEAK WHILE DRIVING. BOTH OF THESE POSE AN EXTREME DANGER OF FIRE HAZARD, AS WELL AS A HEALTH RISK FROM CONSTANTLY INHALING GASOLINE FUMES. *TR

SMELL OF GAS IN THE CAR CHECKED AND FOUND A POOL OF GAS ON TOP OF FUEL SENDER BELOW THE REAR SEAT BEHIND DRIVER SIDE. *TR

STRONG SMELL OF GASOLINE EVERY TIME I FILL UP AND UNTIL I DRIVE ABOUT 50 MILES. I WAS TOLD BY A GERMAN AUTO REPAIR SHOP THAT IT IS A CRACKED GAS TANK AND THAT THIS IS A SYSTEMIC PROBLEM WITH MERCEDES E-CLASS MODELS FROM 2003-2005. THE SMELL APPEARS TO BE EMANATING FROM THE REAR PASSENGER DRIVER'S SIDE. I HAVE ALSO BEEN TOLD THERE WAS A RECALL FOR THIS EXACT ISSUE IN EUROPE AND ASIA BUT THAT MERCEDES NEVER ISSUED A RECALL IN THE US FOR THIS ISSUE DESPITE BEING EXTREMELY PERVASIVE. I DRIVE MY CHILDREN IN THIS CAR AND I AM INCREASINGLY CONCERNED ABOUT THIS DANGEROUS SITUATION. THE REPAIR PRICE I WAS QUOTED WAS ABOUT $2400. THIS SEEMS LIKE IT SHOULD BE A MERCEDES PROBLEM, NOT A CONSUMER PROBLEM. NOBODY SHOULD EXPECT THEIR GAS TANK TO CRACK AT ANY POINT! *TR

VERY STRONG GAS FUMES WHEN GAS TANK IS FULL. FUMES COMPLETELY PERMEATE MY TWO CAR GARAGE AND ALSO ENTER PASSENGER COMPARTMENT. THE FUMES DISAPPEAR WHEN TANK LEVEL REACHES 7/8 FULL. THERE ARE SEVERAL POSTINGS ON DIFFERENT WEBSITES ON THE WEB REGARDING STRONG GAS ODOR WHEN THE TANK IS FULL ON E MODEL MERCEDES YEARS 2003 TO 2006. THIS IS A SERIOUS ISSUE WITH POTENTIAL FOR EXPLOSIVELY AND/OR FIRE. I CONTACTED MERCEDES REQUESTING THE ISSUANCE OF A SERVICE RECALLED BASED ON THE APPARENT HIGH INCIDENCE. THE COMPANY DOES NOT SEEM INTERESTED IN TAKING ANY ACTION. *TR

THE CAR HAS A VERY STRONG GASOLINE ODOR WHEN THE FUEL TANK IS FULL. THE GASOLINE ODOR PERMEATES THE CABIN AND, WHEN PARKED IN AN ENCLOSED GARAGE, CAUSES A HIGH CONCENTRATION OF GAS FUMES THAT OVERWHELMS A THREE CAR GARAGE AS WELL AS THE 1000 SQUARE FEET LOCATED ABOVE THE GARAGE (EVEN WITH ALL ADJOINING DOORS CLOSED). SHOULD THE GASOLINE CONCENTRATION REACH THE PROPER LEVEL, IT MAY CREATE A FIRE OR EXPLOSION HAZARD. ONCE THE TANK IS 1/8 EMPTY, THE FUEL ODOR GOES AWAY AND DOES NOT RETURN UNTIL THE GAS TANK IS ONCE AGAIN FULL. HAD AUTO CHECKED BY THE LOCAL MERCEDES DEALER AND THEY STATED PROBLEM COULD NOT BE LOCATED BUT I NEEDED TO REPLACE ENTIRE FUEL TANK ASSEMBLY TO RESOLVE ISSUE. TOOK CAR TO INDEPENDENT MECHANIC WHO FOUND SIGNS OF GASOLINE LEAKAGE COMING FROM THE TOP OF THE TANK AND RUNNING DOWN THE DRIVER'S SIDE OF THE TANK. BASED ON RESEARCH CONDUCTED ON THE WEB, IT APPEARS THIS IS A RECURRING PROBLEM WITH E CLASS MERCEDES YEARS 2003 TO 2006. THE POSTINGS FOUND ON SEVERAL MERCEDES BENZ OWNER SITES INDICATES THE PROBLEM HAS BEEN DETECTED SINCE THE CARS WERE NEW. A PERSONAL FRIEND, WITH THE SAME YEAR AND MODEL, HAS EXACTLY THE SAME PROBLEM. THE PREVALENCE OF THE ISSUE INDICATES A DESIGN/ ENGINEERING FAILURE THAT RESULTS IN GASOLINE LEAKING FROM 'SOMEWHERE' IN THE FUEL SYSTEM IN THE VICINITY OF THE FUEL TANK. I REQUEST AN INVESTIGATION INTO THIS ISSUE WITH THE OBJECTIVE OF ORDERING A RECALL TO ADDRESS AN OBVIOUS UNDERDESIGN FUEL SYSTEM COMPONENT. *TR

TL* THE CONTACT OWNS A 2003 MERCEDES BENZ E55. THE CONTACT STATED THAT THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER FOR REPAIRS UNDER A RECALL WHERE A NEW SLEEVE WAS INSTALLED ON THE FUEL CLAMP. THE RECALL CAMPAIGN ID NUMBER WAS NOT AVAILABLE. AFTER THE REPAIR, THE CONTACT NOTICED A FUEL SMELL EMITTING FROM THE VEHICLE AFTER REFUELING. THE VEHICLE WAS NOT TAKEN TO THE DEALER FOR DIAGNOSTICS. THE VEHICLE WAS NOT REPAIRED. THE APPROXIMATE FAILURE MILEAGE WAS 49,000. UPDATED 09/15/11*LJ THE CONSUMER STATED THE RECALL WAS PERFORMED ON THE VEHICLE IN 2008. HOWEVER, THE DEALER ONLY CHANGED ONE FUEL SENDER PUMP AND NOT BOTH. THE SECOND FUEL PUMP IS LEAKING FUEL AND THE DEALER REFUSED TO REPLACE IT FREE OF CHARGE. UPDATED 10/12/11

FUEL LEAK AT FUEL TRANSMITTER PASSENGER SIDE UNDER REAR SEAT. *TR

MY 2003 MERCEDES E55 AMG SEDAN HAS A STRONG SMELL OF FUEL COMING FROM THE VEHICLE. I CONTACTED MY LOCAL DEALER AND THEY SAID THE PROBLEM WAS FIXED BACK IN 2008. APPARENTLY THE PROBLEM HAS NOT BEEN SOLVED AND I FEAR AN EXPLOSION FROM MY GARAGE FILLING UP WITH FUMES AND 2 SOURCES OF FIRE, MY FURNACE AND MY WATER HEATER. *TR

I AM A SINGLE 1 OWNER OF A 2003 MERCEDES BENZ E55 AMG AND IT IS LEAKING FUEL INTO THE BACK SEAT ABOVE THE TANK. THE RECALL THAT WAS ISSUED IN 2008 WERE PERFORMED AND IT IS NOW LEAKING AGAIN, AND HAS WRECKED THE INSULATION ABOVE THE TANK. MB REFUSED TO HELP. *TR

TL* THE CONTACT OWNS A 2003 MERCEDES E55. THE CONTACT WAS DRIVING 35 MPH WHEN HE NOTICED AN OVERPOWERING GASOLINE FUEL ODOR FROM THE VEHICLE INTERIOR. THE DEALER MADE REPAIRS TO THE FUEL TANK SEALS. LATER WHILE REFUELING THE VEHICLE, THE CONTACT NOTICED A LARGE PUDDLE OF GASOLINE UNDER THE VEHICLE. HE FURTHER INSPECTED THE FAILURE AND FOUND A LARGE PUDDLE OF GASOLINE FUEL ATOP THE FUEL TANK. THE CONTACT STATED THE VEHICLE WAS PREVIOUSLY REPAIRED UNDER AN UNKNOWN MANUFACTURER'S RECALL FOR THE FUEL ASSEMBLY IN 2008. THE VEHICLE WAS NOT FURTHER REPAIRED. THE FAILURE MILEAGE WAS 55,000 AND THE CURRENT MILEAGE WAS 64,000.