Other Fuel System Tank Assembly problems of the 2004 Mercedes Benz E500

21 problems related to other fuel system tank assembly have been reported for the 2004 Mercedes Benz E500. The most recently reported issues are listed below.

1 Other Fuel System Tank Assembly problem

Failure Date: 04/02/2021

Vehicle has a recall on replacement of fuel tank. Mercedes benz dealer did not want to honor the recall. When I fill car up with gas it leaks out of the tank and on the ground. Mercedes-benz dealer said I missed the time for the recall. I went to the dealership before the recall ended in 2019 spoke with the service advisor at the mckinney mercedes-benz dealership and I informed him the car was not drivable due to the braking system failure call the spc hydraulic pump. Turns out that is also a recall that is widely known. At that time the car was not drivable and then the pandemic hit so there was no need to take it up there at the time due to covid. Mercedes benz should honor this since this is a safety issue that could lead to a deadly situation if not addressed. They have been deceptive by marking this is an extended warranty issue and not a safety recall issue. They pretty much told me since I don't have my car worked on at the dealership, they don't want to help me in this situation. They mentioned had the car been serviced at the dealership and not at the independent shoo that I used I may have had a better chance at them covering the charges for this tank replacement.

2 Other Fuel System Tank Assembly problem

Failure Date: 03/15/2016

There is a very strong smell of gasoline coming from the back seat. When I fill the gas tank the smell is so strong it fills the entire garage. When I removed the back seat I found a small puddle of gas. I first started noticing the smell in the middle of last month -(March 2016)- and continues to get worse each time I fill the gas tank.

3 Other Fuel System Tank Assembly problem

Failure Date: 03/06/2015

I felled my car up with gas at lunch 12 noon and when I got off work at 5pm the gas fumes were so strong I could breathe in my car. I tuck it to south bay Mercedes Benz and was told that the gas tank has a leak and the gas had leaked in to the cabin behind the back set of my car and that the repairs would be covered by the warranty. It¿s been over 2 weeks and they have no eta on when my car will be fixed. I have a loner but I check online and found that there are a lot of people with this same problem.

4 Other Fuel System Tank Assembly problem

Failure Date: 01/05/2015

Benz E500/55k miles. I have had two major safety issues with the car. One being fuel tank related and the second sbc pump failure while driving. On the first, too little too late, so many years after the incident and purchase of the car, Mercedes Benz has sent a letter covering the repair and parts for 15 years. I think that in itself is an offense and a crime. On the second issue, sbc pump Mercedes Benz refused to give me in detail the effect of failing sbc pump on other parts of the car or the effect of failed sbc pump. More importantly, service managers are telling customers that they are expecting all models equipped with sbc pump to come to the shop. Now that the 10 years is up in most cars and out of warranty. That is a scam when the dealer knows all these customers will come to the shop (because it cannot be fixed in any auto shop) thereby taking advantage of a safety issue. How do car manufacturers get away with things like this and how dealers get away with things like this. The right thing to do is extend the warranty on sbc pump to 15 years just like they did in fuel tank, that way dealer won¿t take advantage and customers have peace of mind and won¿t compromise on safety. Even that is a slap on the wrist compared to the offense and crime.

5 Other Fuel System Tank Assembly problem

Failure Date: 12/13/2014

Tl-the contact owns a 2004 Mercedes Benz E500. The contact stated that while driving approximately 55 mph, the brake pedal was engaged and failed to respond as the brake system failure warning light illuminated. The contact was able to avoid an accident. The vehicle was taken to a dealer where it was diagnosed that the sbc unit needed to replaced. The vehicle was not repaired. On another occasion, the contact stated that while driving at a various speeds, a fuel odor emitted inside the vehicle. The vehicle was taken to a dealer where it was diagnosed that the fuel tank was fractured and needed to be replaced. The vehicle was repaired two separate times however, the failure recurred. The vehicle was taken back to the dealer where it was diagnosed that the reserve tank needed to be replaced. The vehicle was repaired but the failure recurred. The the manufacturer was notified of the failure. The failure mileage was 130,000. Ss.

6 Other Fuel System Tank Assembly problem

Failure Date: 10/25/2014

2004 Mercedes Benz E500 smells of gasoline both inside and around the vehicle after refueling to the full tank level. It has become necessary to leave the garage door open after fueling in order to ventilate the garage and keep fumes out of the house. The odor gradually decreases when the vehicle is driven 40-50 miles and the fuel level in the tank drops.

7 Other Fuel System Tank Assembly problem

Failure Date: 06/18/2014

I filled up my car & noticed a gas smell I was on my way to atlanta for work I had to inhale strong gas fumes for most of my travel. When I got there I took my car to a shop & they discovered my gas tank had a leak and gas was leaking near back seat they gave a me an estimate of about 2500 to fix I was told that this had been a known issue for mercedes but no recall yet which I don't understand. This is very dangerous not only the inhalation of the fumes & gas leaking in a car with electrical wiring & parts that get extremely hot. I don't understand why there hasn't been a recall to fix this since mercedes are aware that the car was manufactured properly. Why should we have to pay to repair poor manufactured products that put our lives in danger.

8 Other Fuel System Tank Assembly problem

Failure Date: 05/01/2014

I just filled up my gas tank noticed my whole house smelled like gasoline. Went outside and my garage floor was covered in gasoline. I have read that many people have experienced this issue.

9 Other Fuel System Tank Assembly problem

Failure Date: 07/20/2013

The contact owns a 2004 mercedes-benz E500. The contact stated that fuel was smelled around the vehicle. The vehicle was taken to the dealer where it was found that the fuel tank needed to be replaced. The vehicle was not repaired. The manufacturer was contacted about the failure. The failure mileage was 115,000.

10 Other Fuel System Tank Assembly problem

Failure Date: 03/20/2013

There was a fuel leak that caused the car to smell of gas when the tank is near full (3/4) to completely filled. The fuel has not been leaking to the ground and I have been unable to pinpoint exact location. When I would go into my closed garage after the car had been parked for a while the smell of fuel is too strong to ignore. My mechanic told me the source is the sending unit and tank assembly. He told me the failure was common and the situation could become very dangerous if ignored. The cost to replace the tank is going to run $2,000. The car has never been damaged and should not require a tank replacement at this point in its lifecycle.

11 Other Fuel System Tank Assembly problem

Failure Date: 03/20/2013

Gas tank leaks at the top near the sending unit. Above 3/4 tank level, leakage takes the form of puddles on the floor under the car an noxious fumes are very strong.

12 Other Fuel System Tank Assembly problem

Failure Date: 03/13/2013

Very strong fuel smell when parked inside the garage. Fuel leaks around the fuel tank. I was afraid to open up the garage door because of the smell/fumes. Very concerned that the car might explode.

13 Other Fuel System Tank Assembly problem

Failure Date: 12/18/2012

Car engine light went on. Dealer replaced charocal cannister. Two weeks later auto repair shop was correcting a shimmy and discovered a leaking fuel tank.

14 Other Fuel System Tank Assembly problem

Failure Date: 10/06/2012

Car was not moving when we noticed a strong odor of gasoline coming from the rear seat area, when we pulled into our garage the odor was so strong we moved the car to the outside to prevent a possible fire in our home, I called the dealer and the service manager immediately told me that he thought the gas tank sender/sensor was leaking and possibly that both sensors were leaking and possibly the tank. He also told me that gasoline could be pooling on top of the gas tank causing the odor. He later called me and confirmed that all of the above had happened and could be repaired for approximately $3250. 00 I ask if this was a recurring problem on this model he said that there were no recalls or warning but they had seen this problem before. I then went on line and found a lot of blogs describing my problem almost identically. In my opinion this is a serious defect in the construction of this car and could and probably will cause serious injury and possibly death to some one riding in this model. I believe there is enough evidence in the recurring blogs that mercedes is quite aware of this serious safety problem and are probably ignoring this very expensive fix, please do not ignore this complaint until someone or several are hurt or killed.

15 Other Fuel System Tank Assembly problem

Failure Date: 10/01/2012

After refueling, fuel fumes were emitted into the vehicle and garage where parked. Extremely overwhelming smell and danger obvious. Taken to mechanic and fuel tank has leak at sensor and sending unit seals. The dealer has refused to repair as no recall issued. Owner found many others with exact same issue on this model series and year online and with mechanics experience. Strong potential for imminent fire hazard. Gasoline fumes are hazardous to vehicle passengers, with numerous medical issues noted in research. Strong enough in cabin to cause dizziness, illness or loss of consciousness.

16 Other Fuel System Tank Assembly problem

Failure Date: 08/22/2012

The fuel tank cannot be filled up completely. Doing so causes the car to smell like gasoline. There seems to be a fuel leak on the tank which causes the gasoline to spill. The odor comes mostly from the back seat of the car. If the tank is filled, the car will have the gasoline odor for weeks even with the windows left open. This is quite dangerous in many ways since I have an infant who is required by law to sit in the backseat rear faced.

17 Other Fuel System Tank Assembly problem

Failure Date: 08/06/2012

We purchased this vehicle recently from a private seller. The first time we filled up the tank, we noticed a very strong gasoline odor. I called the seller and he told me that the only way to avoid that is by not topping off the tank. I figured this wasn't normal, so I started doing some research. Turns out mercedes e class vehicles have a problem with the fuel seal. In fact, there was a recall for this problem, but the local mercedes dealer does not want to honor it because they say it is only for the amg models. But my model has the same problem. Then, upon further investigation, I found that a class action lawsuit against mercedes was being filed this year for the same exact issue concerning e class vehicles from 2003-2009.

18 Other Fuel System Tank Assembly problem

Failure Date: 03/01/2012

After refueling, car had strong odor of fuel leaking. Fills garage with fumes. Worried that pilot light will ignite fumes. Also, fuel gage sticks on 1/2 tank even when tank is empty.

19 Other Fuel System Tank Assembly problem

Failure Date: 12/01/2011

Everytime I fill my fuel tank I've noticed a strong fuel odor. Upon inspection I have found the fuel tank to have traces of fuel on the exterior of tank, so my tank has a leak somewhere.

20 Other Fuel System Tank Assembly problem

Failure Date: 02/25/2009

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. Copy of movie. Wmv updated 05/02/11.

21 Other Fuel System Tank Assembly problem

Failure Date: 12/15/2007

The contact owns a 2004 Mercedes Benz E500. The contact stated that there was a strong odor of fuel emitted inside of the vehicle after refueling. Whenever three gallons or more of fuel was dispensed into the fuel tank, the fuel would spew from the filler neck onto the ground. The vehicle was taken to an authorized dealer and they were unable to provide a remedy. The manufacturer was not made aware of the problem. The approximate failure mileage was 42,000.



E500 Service Bulletins
E500 Defect Investigations