Five problems related to other fuel system tank mounting have been reported for the 2003 Mercedes Benz E320. The most recently reported issues are listed below.
After fuel filter replacement, vehicle operated fine for about 7 miles. While idling a couple of minutes in the driveway upon return from the short trip, the return line hose exiting the fuel filter expanded, ruptured, and sprayed fuel out at a high rate. After hose was repaired, fuel gushed out of evaporative canister discharge tube and purge valve canister. Vise grips placed on the rubber tube leading from the return line to the canister stopped the gusher. New fuel filter that was just installed (pronto pf5416) was suspected to be defective - causing excessive return line fuel volume. With the poor design of the return line plumbing and restriction back to the tank, the excess volume was piling up in the evaporative canister and out the purge valve in a massive gushing leak. Once a second new fuel filter was fitted (purolator f65416), vehicle ran properly again without leakage - however, severe leakage from the top of the evaporative canister was noted during a fillup attempt shortly afterwards. This never occurred in the prior to the filter replacement. From all indications, the design is very poor and susceptible to any conditions which result in excessive return line fuel volume. The amount of fuel pouring out of the top of the evaporative canister assembly and discharge was indeed a fire and environmental hazard - the equivalent of an open fuel pump output discharge. In addition to all of this, during the filter replacement/testing process, loud banging was heard from the tank itself. Removal of the gas cap resulted in a massive pressure release. From my observations as a mechanic with over 25 years experience servicing foreign cars, the ventilation and fuel pressurization system on this vehicle is improperly designed and unsafe. Vehicle was on a lift while being serviced.
Vehicle presented with red light indicating to take vehicle to workshop in red. Braking was extremely difficult, srs system stalled the vehicle, emergency mode was activited,we were unable, at first to turn on the ignition switch. The vehicle operated as if it was paralyzed. We finally got the vehicle to run and turned vehicle into mb dealership. We were informed that the sbc unit was in need of replacement, we were beset with 1,800. 00 repair. The vehicle is very dangerous to drive if you are not prepared for longer stopping distances, thankfully my husband was able to get the vehicle to the dealership. I found myself not strong enough to press on the brake pedal for adequate braking distance. Fuel: upon fueling vehicle, the fuel handle will stop and immense amounts of fuel will spurt out from fuel tank. There is also a smell of gas/fuel in the cabin after fill up. This creates a huge spill and notification to attendant. Takes up a great amount of time to fill up tank. Surprisingly we haven't been charged for fuel spills. Srs: light on for safety response system, shortly after visit at mb dealership. Have not taken vehicle to mb dealership for fear of another expensive repair.
I filled the tank and it leaks on the garage floor at a steady drip underneath the rear driver passenger side tire where the tank sits . . . Notice it leaking from the top of the tank coming down on to the floor. . . I cannot fill the tank and the smell and the amount of gas on the floor I believe is quite hazardous in an enclosed garage underneath a bedroom.
When the gas tank is filled full of fuel a strong odor of fuel is present inside of the car. I have looked under the back seat and seen a small amount of fuel escapes from the fuel system. Since I noticed this I have not filled my car up all the way as long as I don't fill it more than three quarters full the problem does not occur,.
The contact owns 2003 Mercedes Benz E320. The contact stated that there was a strong odor of fuel inside and outside of the vehicle as well as a small amount of fuel leaking onto the ground. The vehicle was taken to an independent mechanic who stated that the fuel tank would need to be replaced. The vehicle had not been repaired. The manufacturer was not notified of the problem. The approximate failure mileage was 110,000.