IllustrationCONSTANT 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
2004 Mercedes Benz E500
Owner reports · Recalls · Investigations
More warning signs than most E500 years
Owner complaints for the 2004 Mercedes Benz E500 are substantially higher than the model-year median of 50.
About this comparison →How this year compares
Owner complaints by model year
Compare all E500 years →Counts vary with age, sales and reporting. They are not failure rates.
What owners reported most
All reported categories
Tap a category to read its complaints. One report may name several components.
When problems were reported
Mileage at the reported incident
70–25K
1225–50K
2450–75K
2975–100K
43100–150K
12150K+
127 reports with mileage · 15 unknown
NHTSA’s mileage field refers to the reported incident, not necessarily the filing date. This shows report counts, not the likelihood of a failure.
What to inspect
Issues worth paying extra attention to based on owner reports.
- Fuel/propulsion System. Review the 56 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Fuel System, Gasoline. Review the 30 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
- Suspension. Review the 23 owner reports in this category and discuss these concerns during a pre-purchase inspection. Read reports →
NHTSA owner reports · September 18, 2026 snapshot.
3 crash reports2 fire reports2 injury reports
What owners actually said
142 reportsGAS 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 …
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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
CATASTROPHIC FAILURE OF FRONT LEFT SUSPENSION STRUT ON A 2004 MERCEDES E500 STATION WAGON. THE CAR HAS AN AIR RIDE SYSTEM WHICH MAINTAINS THE RIGHT HEIGHT OF ALL FOUR CORNERS OF THE CAR. IT HAS BEEN SERVICED REGULARLY BY MERCEDES SINCE PURCHASE. THE AIR BLADDER INSIDE THE STRUT BLEW OUT WHILE PARKED IN FRONT OF MY HOME. THIS RES…
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CATASTROPHIC FAILURE OF FRONT LEFT SUSPENSION STRUT ON A 2004 MERCEDES E500 STATION WAGON. THE CAR HAS AN AIR RIDE SYSTEM WHICH MAINTAINS THE RIGHT HEIGHT OF ALL FOUR CORNERS OF THE CAR. IT HAS BEEN SERVICED REGULARLY BY MERCEDES SINCE PURCHASE. THE AIR BLADDER INSIDE THE STRUT BLEW OUT WHILE PARKED IN FRONT OF MY HOME. THIS RESULTED IN THE RIDE HEIGHT OF THE FRONT OF THE CAR DROPPING IMMEDIATELY WITHOUT WARNING TO THE POINT WHERE THE FRAME WAS BARELY 2" ABOVE THE PAVEMENT. IF THIS HAD HAPPENED AT SPEED ON A ROUGH ROAD OR ONE WITH CROWN OR AN IRREGULAR SURFACE, OR IN HEAVY SNOW, THE FRAME COULD CONTACT THE GROUND CAUSING ANY NUMBER OF POSSIBLE OUTCOMES INCLUDING SEVERE CHASSIS DAMAGE AND TOTAL LOSS OF CONTROL. *KB
MY MERCEDES E500 2004 RANDOMLY LOSES POWER AFTER COMING TO A STOP. I HAVE TO PULL OVER TO THE SIDE AND STOP. I TURN THE ENGINE OFF AND BACK ON AND IT THE POWER IS OK. THE CHECK ENGINE LIGHT GOES OUT AFTER RESTARTING. THIS WOULD HAPPEN ONE OR TWICE A MONTH. I ONLY HAVE 45K ON THE CAR. NOW IT'S HAPPENING QUITE OFTEN. THE CHECK …
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MY MERCEDES E500 2004 RANDOMLY LOSES POWER AFTER COMING TO A STOP. I HAVE TO PULL OVER TO THE SIDE AND STOP. I TURN THE ENGINE OFF AND BACK ON AND IT THE POWER IS OK. THE CHECK ENGINE LIGHT GOES OUT AFTER RESTARTING. THIS WOULD HAPPEN ONE OR TWICE A MONTH. I ONLY HAVE 45K ON THE CAR. NOW IT'S HAPPENING QUITE OFTEN. THE CHECK ENGINE LIGHT WOULD COME ON AND THAN GO OUT AFTER RESTARTING. I HAVE TAKEN IT TO THE DEALER SEVERAL TIMES AND THEY HAVE FOUND NO TROUBLE. THEY GIVE ME THE GAS CAP , BAD GAS, ECT. TODAY I LOST POWER TOOK IN TO THE DEALER AND NOW THEY ARE STATING A POWER TRAIN PROBLEM. I GET NERVOUS ON THE ROAD WAY WHEN I LOSE POWER BECAUSE I CAN NOT SPEED UP AND GET AWAY FROM ON COMING TRAFFIC. THE DEALER IS STATING 2 TO 5 THOUSAND DOLLARS FOR THE REPAIR. THIS CAR HAS LESS THAN 45K AND I KEEP IT IN MINT CONDITION AND ONLY DRIVE IT ON WEEK ENDS. I SEE THAT SEVERAL E500 2004 OWNERS HAVE HAD THE SAME PROBLEM VIA AN ON LINE FORUM FOR 2004 E500. *TR
TL*THE CONTACT OWNS 2004 MERCEDES BENZ E500. THE CONTACT STATED WHILE DRIVING 65 MPH THE WARNING LIGHT "BRAKE FAILURE AND ESP FAILURE" WERE DISPLAYED AND ALSO INDICATED THAT THE CONTACT SHOULD DRIVE ONTO THE EMERGENCY LANE. THE CONTACT WAS UNABLE TO STOP THE VEHICLE BY APPLYING THE BRAKES; HOWEVER, WHEN HE WAS ABLE TO STOP IT BY…
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TL*THE CONTACT OWNS 2004 MERCEDES BENZ E500. THE CONTACT STATED WHILE DRIVING 65 MPH THE WARNING LIGHT "BRAKE FAILURE AND ESP FAILURE" WERE DISPLAYED AND ALSO INDICATED THAT THE CONTACT SHOULD DRIVE ONTO THE EMERGENCY LANE. THE CONTACT WAS UNABLE TO STOP THE VEHICLE BY APPLYING THE BRAKES; HOWEVER, WHEN HE WAS ABLE TO STOP IT BY DOWNSHIFTING AND ENGAGING THE EMERGENCY BRAKE. THE CONTACT STATED THIS COULD HAVE CAUSED A MAJOR CRASH. THE VEHICLE WAS TOWED TO A LOCAL MECHANIC WHO WAS PERFORMING A DIAGNOSTIC TEST WHEN THE COMPLAINT WAS FILED. THE CONTACT DID NOT CALL THE MANUFACTURER. THE CONTACT HAD ALSO VIEWED NUMEROUS COMPLAINTS VIA THE INTERNET REGARDING BRAKE FAILURE FOR HIS YEAR, MAKE AND MODEL VEHICLE. THE CONTACT STATED THE MANUFACTURER WAS NOT ISSUED A RECALL BUT WAS FULLY AWARE OF THE BRAKE SYSTEM FAILURE. THE FAILURE MILEAGE WAS 67,000. UPDATED 01/13/11*BF THE CONSUMER ALSO STATED THERE WAS A SMELL OF GAS. IT WAS DETERMINED THE GAS TANK WAS CRACKED. ALSO, THE FRONT BALL JOINT BROKE. THE CONSUMER HAS SINCE TRADED THE VEHICLE. UPDATED 01/24/11
TL* THE CONTACT OWNS A 2004 MERCEDES BENZ E500. WHILE DRIVING AT APPROXIMATE SPEEDS OF 20 MPH, THE ENTIRE DASH BOARD ILLUMINATED FOLLOWED BY THE ILLUMINATION OF THE BRAKE SYSTEM WARNING LIGHT. THE CONTACT ATTEMPTED TO DEPRESS THE BRAKES BUT THE BRAKES WOULD NOT ENGAGE. THE CONTACT WAS ABLE TO DRIVE TO HIS RESIDENCE WITHOUT INCI…
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TL* THE CONTACT OWNS A 2004 MERCEDES BENZ E500. WHILE DRIVING AT APPROXIMATE SPEEDS OF 20 MPH, THE ENTIRE DASH BOARD ILLUMINATED FOLLOWED BY THE ILLUMINATION OF THE BRAKE SYSTEM WARNING LIGHT. THE CONTACT ATTEMPTED TO DEPRESS THE BRAKES BUT THE BRAKES WOULD NOT ENGAGE. THE CONTACT WAS ABLE TO DRIVE TO HIS RESIDENCE WITHOUT INCIDENT AND UTILIZED THE EMERGENCY BRAKE TO STOP THE VEHICLE. THE CONTACT WAS AWAITING A TOW TO THE DEALER FOR DIAGNOSTIC TESTING. THE FAILURE AND CURRENT MILEAGES WERE 51,000. UPDATED 12/10/10 *BF THE CONSUMER TOOK THE VEHICLE TO THE DEALER AND THEY DIAGNOSED THE PROBLEM AS SENSOTRONIC BRAKING SYSTEM FAILURE. IT WAS REPLACED FREE OF CHARGE UNDER THE MANUFACTURER'S WARRANTY. UPDATED 12/27/10 THE CONSUMER STATED WHEN HE STEPPED ON THE BRAKE, THE VEHICLE NOT RESPOND. THE CONSUMER THEN DECIDED TO USE THE COMBINATION OF THE FOOT BRAKE AND THE HILL WHICH BROUGHT THE VEHICLE TO A STOP. UPDATED 01/31/11
THE AIRMATIC SUSPENSION SYSTEM HAS FAILED 3 TIMES - FIRST IN MARCH 2010, THEN APRIL 2010, AND NOW MAY 2010. IT HAS BEEN IN FOR SERVICE FOR THE FIRST 2 INCIDENTS. THE FIRST TIME, THE CAR DROPPED TO THE GROUND WHILE PARKED, THE SECOND TIME IT WAS SLIGHTLY LOW, AND THEN WHILE DRIVING THE REAR DROPPED AND THE CAR BECAME EXTREMELY …
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THE AIRMATIC SUSPENSION SYSTEM HAS FAILED 3 TIMES - FIRST IN MARCH 2010, THEN APRIL 2010, AND NOW MAY 2010. IT HAS BEEN IN FOR SERVICE FOR THE FIRST 2 INCIDENTS. THE FIRST TIME, THE CAR DROPPED TO THE GROUND WHILE PARKED, THE SECOND TIME IT WAS SLIGHTLY LOW, AND THEN WHILE DRIVING THE REAR DROPPED AND THE CAR BECAME EXTREMELY DIFFICULT TO HANDLE. IT IS NOW DROPPING ON THE RIGHT AGAIN, AND PULLS STRONGLY TO THE RIGHT. SERVICE WAS COMPLETED AT THE DEALER. EVEN THEY HAVE ACKNOWLEDGED THE SYSTEM FAILS, AND FAILS IN A MANNER IN WHICH THE WHOLE SYSTEM IS LIKELY TO GO IN A CHAIN REACTION FASHION. *TR
E500 4MATIC SUSPENSION FAILURE - FRONT AIRMATIC SUSPENSION COLLASPED. CAR CAN NOT BE DRIVEN. *TR
WE HAD NOTICED A STRONG SMELL OF GASOLINE IN OUR GARAGE EACH MORNING JUST AFTER WE HAD FILLED THE CAR WITH GAS. WE TOOK THE MB TO MYERSTAR MERCEDES, THEY FOUND CRACK IN THE UPPER MIDDLE FRONT OF THE PLASTIC FUEL TANK AND HAD TO REPLACE THE FUEL TANK. THIS DEFECT SHOULD NEVER HAVE OCCURRED IN A VEHICLE THAT'S ONLY FIVE YEARS OLD …
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WE HAD NOTICED A STRONG SMELL OF GASOLINE IN OUR GARAGE EACH MORNING JUST AFTER WE HAD FILLED THE CAR WITH GAS. WE TOOK THE MB TO MYERSTAR MERCEDES, THEY FOUND CRACK IN THE UPPER MIDDLE FRONT OF THE PLASTIC FUEL TANK AND HAD TO REPLACE THE FUEL TANK. THIS DEFECT SHOULD NEVER HAVE OCCURRED IN A VEHICLE THAT'S ONLY FIVE YEARS OLD WITH 45,000 MILES. THIS DEFECT COULD HAVE CAUSED AN EXPLOSION AND FIRE IN OUR GARAGE. *TR COPY OF MOVIE.WMV UPDATED 05/02/11 *BF UPDATED 12/29/11 *CN
MY CAR BATTERY KEPT DYEING AND ALL OF THE SPEAKERS ON THE RIGHT SIDE WAS NOT WORKING. IN FACT WHEN THE CAR WAS OFF THOSE SPEAKERS WOULD MAKE STATIC NOISES. I HAD AN ELECTRONIC AUTO STORE LOOK AT THE CAR AND THEY TOLD ME THEY COULD NOT FIND THE PROBLEM, BUT WHEN THEY POSED THE QUESTION TO THEIR ONLINE SITE, THE ANSWER CAME BACK…
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MY CAR BATTERY KEPT DYEING AND ALL OF THE SPEAKERS ON THE RIGHT SIDE WAS NOT WORKING. IN FACT WHEN THE CAR WAS OFF THOSE SPEAKERS WOULD MAKE STATIC NOISES. I HAD AN ELECTRONIC AUTO STORE LOOK AT THE CAR AND THEY TOLD ME THEY COULD NOT FIND THE PROBLEM, BUT WHEN THEY POSED THE QUESTION TO THEIR ONLINE SITE, THE ANSWER CAME BACK AS THE "AUDIO GATEWAY" BEING DEFECTIVE. THEY WERE OTHER OWNERS OF THE SAME CAR WITH THE SAME COMPLAINT AND THIS WAS THE PROBLEM. I TOOK THE CAR TO THE MERCEDES DEALER, TOLD THEM OF THE BATTERY DYEING PROBLEM AND THEIR DIAGNOSIS WAS THE SAME, "AUDIO GATEWAY". I PAID THE DEALER TO FIX THE PROBLEM AND THEY STATED THAT REPLACED THE PART. THE TOTAL COST WAS APPROX. $1,258.00, WHICH INCLUDED LABOR. *TR
Official recalls
324V874000 · Visibility:sun/moon Roof Assembly
Nov 19, 2024
Mercedes-Benz USA, LLC (MBUSA) is recalling certain 2001-2011 C-Class, CLK, E-Class, and CLS vehicles. Please see the recall report for a complete list of models and model years. The glass sunroof panel may not be properly secured and can detach.
Consequence & remedy
Consequence: A detached sunroof panel can become a road hazard, increasing the risk of a crash.
Remedy: Dealers will inspect and replace the sunroof panel as necessary, free of charge. Owner notification letters were mailed January 10, 2025. Owners may contact MBUSA customer service at 1-800-367-6372. This recall is an expansion of previous NHTSA recall number 22V-954. MBUSA's number for this recall is 2024120001/2/3.
22V954000 · Visibility:sun/moon Roof Assembly
Dec 23, 2022
Mercedes-Benz USA, LLC (MBUSA) is recalling certain 2001-2011 C-Class, CLK, E-Class, and CLS vehicles. Please refer to MBUSA's recall report for specific vehicle model details. The glass sunroof panel may not be properly secured and may detach.
Consequence & remedy
Consequence: A detached sunroof panel may become a road hazard, increasing the risk of a crash.
Remedy: Dealers will inspect and replace the sunroof panel as necessary free of charge. Owner notification letters were mailed February 3, 2023. Owners may contact MBUSA customer service at 1-800-367-6372. This recall expands NHTSA recall number 19V-918. MBUSA's numbers for this recall are 2023010004, 2023010005, and 2023010006.
19V918000 · Visibility:sun/moon Roof Assembly
Dec 20, 2019
Mercedes-Benz USA, LLC. (MBUSA) is recalling certain 2001-2011 vehicles. The bonding between the glass panel and the sliding roof frame may deteriorate, possibly resulting in the glass panel detaching from the vehicle. For a full list of the affected models visit: https://static.nhtsa.gov/odi/rcl/2019/RMISC-19V918-4126.pdf
Consequence & remedy
Consequence: A detached glass panel can separate from the vehicle and become a road hazard, increasing the risk of a crash.
Remedy: MBUSA will notify owners, and dealers will inspect the glass panel bonding and replace the sliding roof, as necessary, free of charge. The recall began July 10, 2020. Owners may contact MBUSA customer service at 1-800-367-6372. MBUSA's number for this recall is 2020040011.
Model-level recall history does not show whether a particular VIN is affected or has received a repair. Check a VIN with NHTSA ↗
NHTSA investigations
1EA13003 · Fuel Leakage From The Fuel Tank
Opened Mar 15, 2013 · Closed Dec 19, 2014
Status: closed (inferred from source dates) · Fuel System, Gasoline; Fuel System, Gasoline:delivery; Fuel System, Gasoline:delivery:fuel Pump; Fuel System, Gasoline:delivery:hoses, Lines/piping, And Fittings; Fuel System, Gasoline:storage; Fuel System, Gasoline:storage:tank Assembly
The Office of Defects Investigation (ODI) opened this investigation on January 23, 2012 as PE12-001 based on 20 consumer reports in model year (MY) 2003-2006 E55 AMG vehicles.Based on new reports in other E-Class vehicles, ODI upgraded the investigation to Engineering Analysis (EA) 13-003 on March 15, 2013, and expanded the scope to all E-Class vehicles through MY 2008.The complainants alleged a strong odor of gasoline fuel both inside and outside of their vehicle, particularly after refilling the fuel tank.Many of the complainants noted that the odor subsided or went away after driving some distance thereby lowering the fuel level in the tank.Other owners reported they would only fill the tank to about three quarters full to avoid the odor altogether.Some complainants alleged fuel leaked from the fuel filter/sender, located on the top of the fuel tank on the driver's side, and collected on top of the tank.There were also allegations that the fuel leaks were associated with an Emissions Recall Campaign (No. 2008020001) conducted by Mercedes-Benz USA, LLC (Mercedes) in 2008 on MY 2003-2006 E-Class and CLS-Class AMG models.The issue in the recall involved small cracks in the pressurized outlet fitting of the fuel filter/sender.AMG vehicles are high performance models that operate at higher fuel pressure and use a different fuel filter/sender and fuel pump than non-AMG models.Information on Recall No. 2008020001 is available from the U.S. Environmental Protection Agency (EPA) website at www.EPA.gov.ODI's investigation found various leak sources that are unrelated to the outlet fitting cited in the EPA recall campaign.Through interviews with complainants, field inspections of complaint vehicles, and the collection and laboratory analysis of failed parts, three identifiable leak sources were found.The component parts and areas of the leaks involve the On-Board Diagnostic fuel tank pressure sensor (located on top of the fuel filter/sender), the outlet of the centrally mounted fuel tank fuel filling limiter valve, and the top of the fuel pump. These areas of leakage are located at the top of the fuel tank in unpressurized parts of the fuel system. When the tank is full, fuel can slowly weep/seep from micro-cracks in these components and may collect in cavities on top of the filter/sender, pump, or tank.Contrary to complainant's allegations that fuel entered the inside of their vehicle under the rear seat bench, neither ODI nor Mercedes found a plausible way for this to occur.The fuel tank is located outside of the passenger compartment, attached to the underside of the vehicle.The service access ports for the fuel filter/sender (driver's side) and fuel pump (passenger's side) are located under the rear seat bench, covered by a steel plate, sealed and bolted to the vehicle floor.When technicians service the fuel filter/sender, which has a regularly scheduled 60,000 mile service interval, and/or the fuel pump, the work is performed from inside the vehicle by working through the access ports.By letter dated September 4, 2014, Mercedes has notified the agency that it will extend the original warranty coverage to 15 years and unlimited mileage on Covered Fuel Tank Components in E-Class vehicles in MY 2003-2009 and CLS-Class vehicles in MY 2006-2011.The covered fuel tank components for the warranty extension include the fuel tank, fuel filter/sender, fuel pump, and all related gaskets/seals and retention rings.ODI is closing this investigation based on the manufacturer's extend warranty of the affected fuel system components and in consideration that the nature of the leaks does not appear to present an un
Additional source detail variants (6)
Fuel System, Gasoline:delivery:fuel Pump
The Office of Defects Investigation (ODI) opened this investigation on January 23, 2012 as PE12-001 based on 20 consumer reports in model year (MY) 2003-2006 E55 AMG vehicles.Based on new reports in other E-Class vehicles, ODI upgraded the investigation to Engineering Analysis (EA) 13-003 on March 15, 2013, and expanded the scope to all E-Class vehicles through MY 2008.The complainants alleged a strong odor of gasoline fuel both inside and outside of their vehicle, particularly after refilling the fuel tank.Many of the complainants noted that the odor subsided or went away after driving some distance thereby lowering the fuel level in the tank.Other owners reported they would only fill the tank to about three quarters full to avoid the odor altogether.Some complainants alleged fuel leaked from the fuel filter/sender, located on the top of the fuel tank on the driver's side, and collected on top of the tank.There were also allegations that the fuel leaks were associated with an Emissions Recall Campaign (No. 2008020001) conducted by Mercedes-Benz USA, LLC (Mercedes) in 2008 on MY 2003-2006 E-Class and CLS-Class AMG models.The issue in the recall involved small cracks in the pressurized outlet fitting of the fuel filter/sender.AMG vehicles are high performance models that operate at higher fuel pressure and use a different fuel filter/sender and fuel pump than non-AMG models.Information on Recall No. 2008020001 is available from the U.S. Environmental Protection Agency (EPA) website at www.EPA.gov.ODI's investigation found various leak sources that are unrelated to the outlet fitting cited in the EPA recall campaign.Through interviews with complainants, field inspections of complaint vehicles, and the collection and laboratory analysis of failed parts, three identifiable leak sources were found.The component parts and areas of the leaks involve the On-Board Diagnostic fuel tank pressure sensor (located on top of the fuel filter/sender), the outlet of the centrally mounted fuel tank fuel filling limiter valve, and the top of the fuel pump. These areas of leakage are located at the top of the fuel tank in unpressurized parts of the fuel system. When the tank is full, fuel can slowly weep/seep from micro-cracks in these components and may collect in cavities on top of the filter/sender, pump, or tank.Contrary to complainant's allegations that fuel entered the inside of their vehicle under the rear seat bench, neither ODI nor Mercedes found a plausible way for this to occur.The fuel tank is located outside of the passenger compartment, attached to the underside of the vehicle.The service access ports for the fuel filter/sender (driver's side) and fuel pump (passenger's side) are located under the rear seat bench, covered by a steel plate, sealed and bolted to the vehicle floor.When technicians service the fuel filter/sender, which has a regularly scheduled 60,000 mile service interval, and/or the fuel pump, the work is performed from inside the vehicle by working through the access ports.By letter dated September 4, 2014, Mercedes has notified the agency that it will extend the original warranty coverage to 15 years and unlimited mileage on Covered Fuel Tank Components in E-Class vehicles in MY 2003-2009 and CLS-Class vehicles in MY 2006-2011.The covered fuel tank components for the warranty extension include the fuel tank, fuel filter/sender, fuel pump, and all related gaskets/seals and retention rings.ODI is closing this investigation based on the manufacturer's extend warranty of the affected fuel system components and in consideration that the nature of the leaks does not appear to present an un
Fuel System, Gasoline:delivery:hoses, Lines/piping, And Fittings
The Office of Defects Investigation (ODI) opened this investigation on January 23, 2012 as PE12-001 based on 20 consumer reports in model year (MY) 2003-2006 E55 AMG vehicles.Based on new reports in other E-Class vehicles, ODI upgraded the investigation to Engineering Analysis (EA) 13-003 on March 15, 2013, and expanded the scope to all E-Class vehicles through MY 2008.The complainants alleged a strong odor of gasoline fuel both inside and outside of their vehicle, particularly after refilling the fuel tank.Many of the complainants noted that the odor subsided or went away after driving some distance thereby lowering the fuel level in the tank.Other owners reported they would only fill the tank to about three quarters full to avoid the odor altogether.Some complainants alleged fuel leaked from the fuel filter/sender, located on the top of the fuel tank on the driver's side, and collected on top of the tank.There were also allegations that the fuel leaks were associated with an Emissions Recall Campaign (No. 2008020001) conducted by Mercedes-Benz USA, LLC (Mercedes) in 2008 on MY 2003-2006 E-Class and CLS-Class AMG models.The issue in the recall involved small cracks in the pressurized outlet fitting of the fuel filter/sender.AMG vehicles are high performance models that operate at higher fuel pressure and use a different fuel filter/sender and fuel pump than non-AMG models.Information on Recall No. 2008020001 is available from the U.S. Environmental Protection Agency (EPA) website at www.EPA.gov.ODI's investigation found various leak sources that are unrelated to the outlet fitting cited in the EPA recall campaign.Through interviews with complainants, field inspections of complaint vehicles, and the collection and laboratory analysis of failed parts, three identifiable leak sources were found.The component parts and areas of the leaks involve the On-Board Diagnostic fuel tank pressure sensor (located on top of the fuel filter/sender), the outlet of the centrally mounted fuel tank fuel filling limiter valve, and the top of the fuel pump. These areas of leakage are located at the top of the fuel tank in unpressurized parts of the fuel system. When the tank is full, fuel can slowly weep/seep from micro-cracks in these components and may collect in cavities on top of the filter/sender, pump, or tank.Contrary to complainant's allegations that fuel entered the inside of their vehicle under the rear seat bench, neither ODI nor Mercedes found a plausible way for this to occur.The fuel tank is located outside of the passenger compartment, attached to the underside of the vehicle.The service access ports for the fuel filter/sender (driver's side) and fuel pump (passenger's side) are located under the rear seat bench, covered by a steel plate, sealed and bolted to the vehicle floor.When technicians service the fuel filter/sender, which has a regularly scheduled 60,000 mile service interval, and/or the fuel pump, the work is performed from inside the vehicle by working through the access ports.By letter dated September 4, 2014, Mercedes has notified the agency that it will extend the original warranty coverage to 15 years and unlimited mileage on Covered Fuel Tank Components in E-Class vehicles in MY 2003-2009 and CLS-Class vehicles in MY 2006-2011.The covered fuel tank components for the warranty extension include the fuel tank, fuel filter/sender, fuel pump, and all related gaskets/seals and retention rings.ODI is closing this investigation based on the manufacturer's extend warranty of the affected fuel system components and in consideration that the nature of the leaks does not appear to present an un
Fuel System, Gasoline:delivery
The Office of Defects Investigation (ODI) opened this investigation on January 23, 2012 as PE12-001 based on 20 consumer reports in model year (MY) 2003-2006 E55 AMG vehicles.Based on new reports in other E-Class vehicles, ODI upgraded the investigation to Engineering Analysis (EA) 13-003 on March 15, 2013, and expanded the scope to all E-Class vehicles through MY 2008.The complainants alleged a strong odor of gasoline fuel both inside and outside of their vehicle, particularly after refilling the fuel tank.Many of the complainants noted that the odor subsided or went away after driving some distance thereby lowering the fuel level in the tank.Other owners reported they would only fill the tank to about three quarters full to avoid the odor altogether.Some complainants alleged fuel leaked from the fuel filter/sender, located on the top of the fuel tank on the driver's side, and collected on top of the tank.There were also allegations that the fuel leaks were associated with an Emissions Recall Campaign (No. 2008020001) conducted by Mercedes-Benz USA, LLC (Mercedes) in 2008 on MY 2003-2006 E-Class and CLS-Class AMG models.The issue in the recall involved small cracks in the pressurized outlet fitting of the fuel filter/sender.AMG vehicles are high performance models that operate at higher fuel pressure and use a different fuel filter/sender and fuel pump than non-AMG models.Information on Recall No. 2008020001 is available from the U.S. Environmental Protection Agency (EPA) website at www.EPA.gov.ODI's investigation found various leak sources that are unrelated to the outlet fitting cited in the EPA recall campaign.Through interviews with complainants, field inspections of complaint vehicles, and the collection and laboratory analysis of failed parts, three identifiable leak sources were found.The component parts and areas of the leaks involve the On-Board Diagnostic fuel tank pressure sensor (located on top of the fuel filter/sender), the outlet of the centrally mounted fuel tank fuel filling limiter valve, and the top of the fuel pump. These areas of leakage are located at the top of the fuel tank in unpressurized parts of the fuel system. When the tank is full, fuel can slowly weep/seep from micro-cracks in these components and may collect in cavities on top of the filter/sender, pump, or tank.Contrary to complainant's allegations that fuel entered the inside of their vehicle under the rear seat bench, neither ODI nor Mercedes found a plausible way for this to occur.The fuel tank is located outside of the passenger compartment, attached to the underside of the vehicle.The service access ports for the fuel filter/sender (driver's side) and fuel pump (passenger's side) are located under the rear seat bench, covered by a steel plate, sealed and bolted to the vehicle floor.When technicians service the fuel filter/sender, which has a regularly scheduled 60,000 mile service interval, and/or the fuel pump, the work is performed from inside the vehicle by working through the access ports.By letter dated September 4, 2014, Mercedes has notified the agency that it will extend the original warranty coverage to 15 years and unlimited mileage on Covered Fuel Tank Components in E-Class vehicles in MY 2003-2009 and CLS-Class vehicles in MY 2006-2011.The covered fuel tank components for the warranty extension include the fuel tank, fuel filter/sender, fuel pump, and all related gaskets/seals and retention rings.ODI is closing this investigation based on the manufacturer's extend warranty of the affected fuel system components and in consideration that the nature of the leaks does not appear to present an un
Fuel System, Gasoline
The Office of Defects Investigation (ODI) opened this investigation on January 23, 2012 as PE12-001 based on 20 consumer reports in model year (MY) 2003-2006 E55 AMG vehicles.Based on new reports in other E-Class vehicles, ODI upgraded the investigation to Engineering Analysis (EA) 13-003 on March 15, 2013, and expanded the scope to all E-Class vehicles through MY 2008.The complainants alleged a strong odor of gasoline fuel both inside and outside of their vehicle, particularly after refilling the fuel tank.Many of the complainants noted that the odor subsided or went away after driving some distance thereby lowering the fuel level in the tank.Other owners reported they would only fill the tank to about three quarters full to avoid the odor altogether.Some complainants alleged fuel leaked from the fuel filter/sender, located on the top of the fuel tank on the driver's side, and collected on top of the tank.There were also allegations that the fuel leaks were associated with an Emissions Recall Campaign (No. 2008020001) conducted by Mercedes-Benz USA, LLC (Mercedes) in 2008 on MY 2003-2006 E-Class and CLS-Class AMG models.The issue in the recall involved small cracks in the pressurized outlet fitting of the fuel filter/sender.AMG vehicles are high performance models that operate at higher fuel pressure and use a different fuel filter/sender and fuel pump than non-AMG models.Information on Recall No. 2008020001 is available from the U.S. Environmental Protection Agency (EPA) website at www.EPA.gov.ODI's investigation found various leak sources that are unrelated to the outlet fitting cited in the EPA recall campaign.Through interviews with complainants, field inspections of complaint vehicles, and the collection and laboratory analysis of failed parts, three identifiable leak sources were found.The component parts and areas of the leaks involve the On-Board Diagnostic fuel tank pressure sensor (located on top of the fuel filter/sender), the outlet of the centrally mounted fuel tank fuel filling limiter valve, and the top of the fuel pump. These areas of leakage are located at the top of the fuel tank in unpressurized parts of the fuel system. When the tank is full, fuel can slowly weep/seep from micro-cracks in these components and may collect in cavities on top of the filter/sender, pump, or tank.Contrary to complainant's allegations that fuel entered the inside of their vehicle under the rear seat bench, neither ODI nor Mercedes found a plausible way for this to occur.The fuel tank is located outside of the passenger compartment, attached to the underside of the vehicle.The service access ports for the fuel filter/sender (driver's side) and fuel pump (passenger's side) are located under the rear seat bench, covered by a steel plate, sealed and bolted to the vehicle floor.When technicians service the fuel filter/sender, which has a regularly scheduled 60,000 mile service interval, and/or the fuel pump, the work is performed from inside the vehicle by working through the access ports.By letter dated September 4, 2014, Mercedes has notified the agency that it will extend the original warranty coverage to 15 years and unlimited mileage on Covered Fuel Tank Components in E-Class vehicles in MY 2003-2009 and CLS-Class vehicles in MY 2006-2011.The covered fuel tank components for the warranty extension include the fuel tank, fuel filter/sender, fuel pump, and all related gaskets/seals and retention rings.ODI is closing this investigation based on the manufacturer's extend warranty of the affected fuel system components and in consideration that the nature of the leaks does not appear to present an un
Fuel System, Gasoline:storage
The Office of Defects Investigation (ODI) opened this investigation on January 23, 2012 as PE12-001 based on 20 consumer reports in model year (MY) 2003-2006 E55 AMG vehicles.Based on new reports in other E-Class vehicles, ODI upgraded the investigation to Engineering Analysis (EA) 13-003 on March 15, 2013, and expanded the scope to all E-Class vehicles through MY 2008.The complainants alleged a strong odor of gasoline fuel both inside and outside of their vehicle, particularly after refilling the fuel tank.Many of the complainants noted that the odor subsided or went away after driving some distance thereby lowering the fuel level in the tank.Other owners reported they would only fill the tank to about three quarters full to avoid the odor altogether.Some complainants alleged fuel leaked from the fuel filter/sender, located on the top of the fuel tank on the driver's side, and collected on top of the tank.There were also allegations that the fuel leaks were associated with an Emissions Recall Campaign (No. 2008020001) conducted by Mercedes-Benz USA, LLC (Mercedes) in 2008 on MY 2003-2006 E-Class and CLS-Class AMG models.The issue in the recall involved small cracks in the pressurized outlet fitting of the fuel filter/sender.AMG vehicles are high performance models that operate at higher fuel pressure and use a different fuel filter/sender and fuel pump than non-AMG models.Information on Recall No. 2008020001 is available from the U.S. Environmental Protection Agency (EPA) website at www.EPA.gov.ODI's investigation found various leak sources that are unrelated to the outlet fitting cited in the EPA recall campaign.Through interviews with complainants, field inspections of complaint vehicles, and the collection and laboratory analysis of failed parts, three identifiable leak sources were found.The component parts and areas of the leaks involve the On-Board Diagnostic fuel tank pressure sensor (located on top of the fuel filter/sender), the outlet of the centrally mounted fuel tank fuel filling limiter valve, and the top of the fuel pump. These areas of leakage are located at the top of the fuel tank in unpressurized parts of the fuel system. When the tank is full, fuel can slowly weep/seep from micro-cracks in these components and may collect in cavities on top of the filter/sender, pump, or tank.Contrary to complainant's allegations that fuel entered the inside of their vehicle under the rear seat bench, neither ODI nor Mercedes found a plausible way for this to occur.The fuel tank is located outside of the passenger compartment, attached to the underside of the vehicle.The service access ports for the fuel filter/sender (driver's side) and fuel pump (passenger's side) are located under the rear seat bench, covered by a steel plate, sealed and bolted to the vehicle floor.When technicians service the fuel filter/sender, which has a regularly scheduled 60,000 mile service interval, and/or the fuel pump, the work is performed from inside the vehicle by working through the access ports.By letter dated September 4, 2014, Mercedes has notified the agency that it will extend the original warranty coverage to 15 years and unlimited mileage on Covered Fuel Tank Components in E-Class vehicles in MY 2003-2009 and CLS-Class vehicles in MY 2006-2011.The covered fuel tank components for the warranty extension include the fuel tank, fuel filter/sender, fuel pump, and all related gaskets/seals and retention rings.ODI is closing this investigation based on the manufacturer's extend warranty of the affected fuel system components and in consideration that the nature of the leaks does not appear to present an un
Fuel System, Gasoline:storage:tank Assembly
The Office of Defects Investigation (ODI) opened this investigation on January 23, 2012 as PE12-001 based on 20 consumer reports in model year (MY) 2003-2006 E55 AMG vehicles.Based on new reports in other E-Class vehicles, ODI upgraded the investigation to Engineering Analysis (EA) 13-003 on March 15, 2013, and expanded the scope to all E-Class vehicles through MY 2008.The complainants alleged a strong odor of gasoline fuel both inside and outside of their vehicle, particularly after refilling the fuel tank.Many of the complainants noted that the odor subsided or went away after driving some distance thereby lowering the fuel level in the tank.Other owners reported they would only fill the tank to about three quarters full to avoid the odor altogether.Some complainants alleged fuel leaked from the fuel filter/sender, located on the top of the fuel tank on the driver's side, and collected on top of the tank.There were also allegations that the fuel leaks were associated with an Emissions Recall Campaign (No. 2008020001) conducted by Mercedes-Benz USA, LLC (Mercedes) in 2008 on MY 2003-2006 E-Class and CLS-Class AMG models.The issue in the recall involved small cracks in the pressurized outlet fitting of the fuel filter/sender.AMG vehicles are high performance models that operate at higher fuel pressure and use a different fuel filter/sender and fuel pump than non-AMG models.Information on Recall No. 2008020001 is available from the U.S. Environmental Protection Agency (EPA) website at www.EPA.gov.ODI's investigation found various leak sources that are unrelated to the outlet fitting cited in the EPA recall campaign.Through interviews with complainants, field inspections of complaint vehicles, and the collection and laboratory analysis of failed parts, three identifiable leak sources were found.The component parts and areas of the leaks involve the On-Board Diagnostic fuel tank pressure sensor (located on top of the fuel filter/sender), the outlet of the centrally mounted fuel tank fuel filling limiter valve, and the top of the fuel pump. These areas of leakage are located at the top of the fuel tank in unpressurized parts of the fuel system. When the tank is full, fuel can slowly weep/seep from micro-cracks in these components and may collect in cavities on top of the filter/sender, pump, or tank.Contrary to complainant's allegations that fuel entered the inside of their vehicle under the rear seat bench, neither ODI nor Mercedes found a plausible way for this to occur.The fuel tank is located outside of the passenger compartment, attached to the underside of the vehicle.The service access ports for the fuel filter/sender (driver's side) and fuel pump (passenger's side) are located under the rear seat bench, covered by a steel plate, sealed and bolted to the vehicle floor.When technicians service the fuel filter/sender, which has a regularly scheduled 60,000 mile service interval, and/or the fuel pump, the work is performed from inside the vehicle by working through the access ports.By letter dated September 4, 2014, Mercedes has notified the agency that it will extend the original warranty coverage to 15 years and unlimited mileage on Covered Fuel Tank Components in E-Class vehicles in MY 2003-2009 and CLS-Class vehicles in MY 2006-2011.The covered fuel tank components for the warranty extension include the fuel tank, fuel filter/sender, fuel pump, and all related gaskets/seals and retention rings.ODI is closing this investigation based on the manufacturer's extend warranty of the affected fuel system components and in consideration that the nature of the leaks does not appear to present an un