Tank Filler Pipe And Cap problems of the 2004 Mercedes Benz E55

The vehicle was repaired by the previous owner at mercedes under a recall, for the fuel leaks. The vehicle threw a code for gas cap. I replaced the gas cap. Two days later the check engine light disappeared and the car threw a code for an evap leak. I replaced the charcoal canister and the gas cap thinking it may have been faulty. The vehicle continues to throw a check engine light when it is filled with gasoline. Once the tank level drops below 3/4 the warning goes away however the check engine light remains.

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.

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.