URGENT: NHTSA Opens investigation into fuel leaks on the W211 E Class
Newbie
Joined: May 2012
Posts: 1
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E320 2004
PB62
Thank you for posting this message. It appears that this is a very common problem that has affected or will almost invariably affect most owners of W211 E Class cars. I drive a 2004 model E320 and have experienced the same issue described in detail by others in this forum. After filling up the fuel tank to full capacity I have first detected a strong smell of fuel inside the cabin and then gasoline fumes were also emanating from the rear left wheel well. The plastic cover of the fuel sender unit on the driver's side contained about 200 cc of leaked gasoline. The dealer declined to cover the cost of replacing the sender unit and fuel tank and offered only a 25% of good faith discount that would still amount to about $2000 in repair cost. This is an egregious manufacturer's design flow and material defect that causes an indisputable fire hazard and inhalation of toxic gasoline vapors by the occupants of the car. I can not believe this is happening with a Mercedes. I have filed a formal complaint with the NHTSA today.
https://mbworld.org/forums/w211-amg/...leaks-e55.html
This involves all W211 E Class cars as they have all had problems with leaking fuel sending units and tanks. The National Highway Transportation Safety Authority has a CURRENTLY OPEN INVESTIGATION in regards to these problems and we need anyone that has not yet filed a complaint with NHTSA to do so ASAP.
Mercedes is finally being forced to answer to this problem and the NHTSA needs to know the scope of this problem. There is a good chance that a safety recall may come from this so action is needed from anyone that has not reported their failures yet.
COMPLAINTS CAN BE FILED HERE: https://www-odi.nhtsa.dot.gov/ivoq/
Reference NHTSA Action Number: PE12001.
This involves all W211 E Class cars as they have all had problems with leaking fuel sending units and tanks. The National Highway Transportation Safety Authority has a CURRENTLY OPEN INVESTIGATION in regards to these problems and we need anyone that has not yet filed a complaint with NHTSA to do so ASAP.
Mercedes is finally being forced to answer to this problem and the NHTSA needs to know the scope of this problem. There is a good chance that a safety recall may come from this so action is needed from anyone that has not reported their failures yet.
COMPLAINTS CAN BE FILED HERE: https://www-odi.nhtsa.dot.gov/ivoq/
Reference NHTSA Action Number: PE12001.
Junior Member
Joined: Apr 2012
Posts: 29
Likes: 3
2007 E550 4matic
I'm still slightly shocked that the W211s have fuel leakage issues. In my 25 years of owning cars, I've never had a car with fuel issues like this. The closest would be failures of integrated sender/fuel level assemblies, but those never caused external leaks--they simply failed and stopped functioning.
It seems like the W211 has leakage problems with all major components: the tank, the sender unit, and the various vapor recovery assemblies.
This seems like it could develop into really bad PR for Mercedes if these problems become widely known.
It seems like the W211 has leakage problems with all major components: the tank, the sender unit, and the various vapor recovery assemblies.
This seems like it could develop into really bad PR for Mercedes if these problems become widely known.
Senior Member
Joined: May 2011
Posts: 250
Likes: 1
From: Earth
2012 W212 | 2016 W205
Does it affect diesel models too?
I usually fill mine up to the brim and i don't get any leakage problems.
Why don't you just take your car to an engineering firm, or a business that does welding they can remove your tank, pressure test it and spot weld any holes?
Thats what i'd be doing instead of going back to the dealer and paying stupid amounts of money.
I usually fill mine up to the brim and i don't get any leakage problems.
Why don't you just take your car to an engineering firm, or a business that does welding they can remove your tank, pressure test it and spot weld any holes?
Thats what i'd be doing instead of going back to the dealer and paying stupid amounts of money.
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Joined: Nov 2005
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none
Update:
Someone had a meeting with Mercedes Benz. 5.22.2012
Perhaps the incident in Australia had something to do with it????
http://www-odi.nhtsa.dot.gov/acms/cs...2001-51394.pdf
Someone had a meeting with Mercedes Benz. 5.22.2012
Perhaps the incident in Australia had something to do with it????
http://www-odi.nhtsa.dot.gov/acms/cs...2001-51394.pdf
Last edited by moosejaw; May 24, 2012 at 09:25 AM.
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Super Member
Joined: Sep 2005
Posts: 723
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From: Central Jersey
2003 E500, 2004 G35X
Update:
Someone had a meeting with Mercedes Benz. 5.22.2012
Perhaps the incident in Australia had something to do with it????
http://www-odi.nhtsa.dot.gov/acms/cs...2001-51394.pdf
Someone had a meeting with Mercedes Benz. 5.22.2012
Perhaps the incident in Australia had something to do with it????
http://www-odi.nhtsa.dot.gov/acms/cs...2001-51394.pdf
Junior Member
Joined: Apr 2012
Posts: 29
Likes: 3
2007 E550 4matic
The memo to file is dated 5/22/12, but only documents a meeting held on 4/13/12. This is normal agency procedure--they attempt to document all meetings in an effort to avoid accusations of inappropriate ex parte communications.
Wasn't 4/13/12 prior to the long reply submitted by MB's counsel? The one stating that nothing is wrong with the W211's fuel system, or in the alternative that dealers are breaking things while performing repairs.
Wasn't 4/13/12 prior to the long reply submitted by MB's counsel? The one stating that nothing is wrong with the W211's fuel system, or in the alternative that dealers are breaking things while performing repairs.
Last edited by Kwijibo; May 24, 2012 at 03:12 PM.
Junior Member
Joined: Apr 2012
Posts: 29
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2007 E550 4matic
I removed the fuel sender access panel to investigate my fuel smell. I've attached a photo of what I found. I assume all the dark-stained plastic is where gasoline has leaked in the past.
There is no damage on this part at all--it has merely failed! It appears whatever material MB used degrades from contact with gasoline.
What are my repair options? It looks like I have leakage not only around the perimeter (a new seal might fix this), but also from the electrical connector in the center of the unit (there is no separate seal, a new sender appears to be the only fix).
I previously opened a complaint with NHTSA. Is there any way to add this photo to my complaint? The MB response mentioned that human perception of gasoline fumes was more acute than the allowable vapor release. This is no mere vapor release--this is a leak!
There is no damage on this part at all--it has merely failed! It appears whatever material MB used degrades from contact with gasoline.
What are my repair options? It looks like I have leakage not only around the perimeter (a new seal might fix this), but also from the electrical connector in the center of the unit (there is no separate seal, a new sender appears to be the only fix).
I previously opened a complaint with NHTSA. Is there any way to add this photo to my complaint? The MB response mentioned that human perception of gasoline fumes was more acute than the allowable vapor release. This is no mere vapor release--this is a leak!
Last edited by Kwijibo; Jun 10, 2012 at 11:27 AM. Reason: More info.
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2009 SL550 Roadster Diamond White, 2008 CLK550 Coupe Obsidian Black
I removed the fuel sender access panel to investigate my fuel smell. I've attached a photo of what I found. I assume all the dark-stained plastic is where gasoline has leaked in the past.
There is no damage on this part at all--it has merely failed! It appears whatever material MB used degrades from contact with gasoline.
What are my repair options? It looks like I have leakage not only around the perimeter (a new seal might fix this), but also from the electrical connector in the center of the unit (there is no separate seal, a new sender appears to be the only fix).
I previously opened a complaint with NHTSA. Is there any way to add this photo to my complaint? The MB response mentioned that human perception of gasoline fumes was more acute than the allowable vapor release. This is no mere vapor release--this is a leak!
There is no damage on this part at all--it has merely failed! It appears whatever material MB used degrades from contact with gasoline.
What are my repair options? It looks like I have leakage not only around the perimeter (a new seal might fix this), but also from the electrical connector in the center of the unit (there is no separate seal, a new sender appears to be the only fix).
I previously opened a complaint with NHTSA. Is there any way to add this photo to my complaint? The MB response mentioned that human perception of gasoline fumes was more acute than the allowable vapor release. This is no mere vapor release--this is a leak!
I would just start with new seals (as I did). My indy said the next thing he would do is the hoses or something that go from the tank. He said if that didn't fix it, he would have to go to for the sending units and the entire tank
Super Member
Joined: Sep 2005
Posts: 723
Likes: 32
From: Central Jersey
2003 E500, 2004 G35X
I removed the fuel sender access panel to investigate my fuel smell. I've attached a photo of what I found. I assume all the dark-stained plastic is where gasoline has leaked in the past.
There is no damage on this part at all--it has merely failed! It appears whatever material MB used degrades from contact with gasoline.
What are my repair options? It looks like I have leakage not only around the perimeter (a new seal might fix this), but also from the electrical connector in the center of the unit (there is no separate seal, a new sender appears to be the only fix).
I previously opened a complaint with NHTSA. Is there any way to add this photo to my complaint? The MB response mentioned that human perception of gasoline fumes was more acute than the allowable vapor release. This is no mere vapor release--this is a leak!
There is no damage on this part at all--it has merely failed! It appears whatever material MB used degrades from contact with gasoline.
What are my repair options? It looks like I have leakage not only around the perimeter (a new seal might fix this), but also from the electrical connector in the center of the unit (there is no separate seal, a new sender appears to be the only fix).
I previously opened a complaint with NHTSA. Is there any way to add this photo to my complaint? The MB response mentioned that human perception of gasoline fumes was more acute than the allowable vapor release. This is no mere vapor release--this is a leak!
Senior Member
Joined: Mar 2010
Posts: 451
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2007 E350; 2018 GLE350
I removed the fuel sender access panel to investigate my fuel smell. I've attached a photo of what I found. I assume all the dark-stained plastic is where gasoline has leaked in the past.
There is no damage on this part at all--it has merely failed! It appears whatever material MB used degrades from contact with gasoline.
What are my repair options? It looks like I have leakage not only around the perimeter (a new seal might fix this), but also from the electrical connector in the center of the unit (there is no separate seal, a new sender appears to be the only fix).
I previously opened a complaint with NHTSA. Is there any way to add this photo to my complaint? The MB response mentioned that human perception of gasoline fumes was more acute than the allowable vapor release. This is no mere vapor release--this is a leak!
There is no damage on this part at all--it has merely failed! It appears whatever material MB used degrades from contact with gasoline.
What are my repair options? It looks like I have leakage not only around the perimeter (a new seal might fix this), but also from the electrical connector in the center of the unit (there is no separate seal, a new sender appears to be the only fix).
I previously opened a complaint with NHTSA. Is there any way to add this photo to my complaint? The MB response mentioned that human perception of gasoline fumes was more acute than the allowable vapor release. This is no mere vapor release--this is a leak!
Evidence of gasoline getting to the outside of the sending unit should prompt MB to take effective action to cure this problem. Right now, this is merely an engineering/design/manufacturing/installation problem. They don't want it to become a legal problem.
Junior Member
Joined: Apr 2012
Posts: 29
Likes: 3
2007 E550 4matic
About your picture: I see two discolorations on your sending unit. One is black ... and looks like it might be wet gasoline. The other is brownish orange ... and looks like it might be a stain from prior contact with gasoline. Am I misreading or misunderstanding the evidence?
Evidence of gasoline getting to the outside of the sending unit should prompt MB to take effective action to cure this problem. Right now, this is merely an engineering/design/manufacturing/installation problem. They don't want it to become a legal problem.
Evidence of gasoline getting to the outside of the sending unit should prompt MB to take effective action to cure this problem. Right now, this is merely an engineering/design/manufacturing/installation problem. They don't want it to become a legal problem.
I also see evidence to the rear of the sending unit that gasoline has flowed on the surface of the gas tank itself--some of the dirt is dislodged in a liquid flow shape. It appears the external tank flow matches exactly with the stain from the locking ring.
I assume the orange discoloration is the result of contact with gasoline. What has me mostly concerned is that the leak does not seem to be limited to the seal perimeter or the high-pressure outlet. I see evidence of leakage from the top of the foreground electrical connector.
I also checked the passenger-side unit. Since it has a different function, the physical appearance is completely different from the driver-side unit. There appear to be no issues on the passenger-side--the area is completely dry with no evidence of past leakage.
Last edited by Kwijibo; Jun 11, 2012 at 10:23 AM.
Newbie
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Mercedes E-350
About to purchase E350
This is my first post to MBWorld. I have been researching issues with 2009 E 350 before making an offer. This thread was disconcerting, but I am very appreciative of the info and have learned a lot. One thing I gleaned from the discussions was to request a pre-purchase inspection. I'd like to have them check the fuel sender unit. If it has a problem should I walk away or see if they will replace? Even if the dlr replaces parts, aren't they simply replacing the defectiveparts (if damage not caused by ethanol) with parts having the same problem? Is there anything else I should prepare to ask them to inspect? Thank you for the sage advice.
Super Member
Joined: Sep 2005
Posts: 723
Likes: 32
From: Central Jersey
2003 E500, 2004 G35X
This is my first post to MBWorld. I have been researching issues with 2009 E 350 before making an offer. This thread was disconcerting, but I am very appreciative of the info and have learned a lot. One thing I gleaned from the discussions was to request a pre-purchase inspection. I'd like to have them check the fuel sender unit. If it has a problem should I walk away or see if they will replace? Even if the dlr replaces parts, aren't they simply replacing the defectiveparts (if damage not caused by ethanol) with parts having the same problem? Is there anything else I should prepare to ask them to inspect? Thank you for the sage advice.
Newbie
Joined: Jun 2012
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Mercedes E-350
Fuel Leak Dealer Response So Far
Just got back from the dealer. I showed them the NHTSA letter dated 4/13/2012. They agreed to top off the tank and check for a gas odor or leak while I'm there. They also offered to replace a rear tire with 5/10th tread remaining. The other rear tire still had 8/10th. The front tires are new. They also offered a full inspection and for me to talk with their senior MB mechanic of 40 years. The salesman emailed me with a statement from the mechanic that "the E class has been the most problem free car they have had". Wonder if he's ever worked on Hondas. I'm keeping an open mind but haven't opened my wallet just yet. Thanks much.
MBWorld Fanatic!
Joined: Mar 2006
Posts: 3,254
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From: Louisiana
03 E500 and Corvette
Just got back from the dealer. I showed them the NHTSA letter dated 4/13/2012. They agreed to top off the tank and check for a gas odor or leak while I'm there. They also offered to replace a rear tire with 5/10th tread remaining. The other rear tire still had 8/10th. The front tires are new. They also offered a full inspection and for me to talk with their senior MB mechanic of 40 years. The salesman emailed me with a statement from the mechanic that "the E class has been the most problem free car they have had". Wonder if he's ever worked on Hondas. I'm keeping an open mind but haven't opened my wallet just yet. Thanks much.
Now with that statement I would question the mechanic's experience. He must be talking warranty claims on 2012.
Airmatic, SBC,, Air Springs, $1000 shocks. Fuel leaks, and the list goes on.!
Super Member
Joined: Sep 2005
Posts: 723
Likes: 32
From: Central Jersey
2003 E500, 2004 G35X
WOW! "statement from the mechanic that "the E class has been the most problem free car they have had"
Now with that statement I would question the mechanic's experience. He must be talking warranty claims on 2012.
Airmatic, SBC,, Air Springs, $1000 shocks. Fuel leaks, and the list goes on.!
Now with that statement I would question the mechanic's experience. He must be talking warranty claims on 2012.
Airmatic, SBC,, Air Springs, $1000 shocks. Fuel leaks, and the list goes on.!
MB refused to acknowledge the gas odor problem and only NHTSA can make MB do it.
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From: Ft. Lauderdale Area, USA
2015 ML 350
Unbelieveable! The E Class in general over the years, maybe... the 211? absolutely an outright lie. The 211 overall lost them money, respect and customers. Big damage to the brand. (Remember the 211s caused MB to fall to dead last from near the top in JD Powers) Many parts failures, erratic behavior of all electrics, not a great 7 spd transmission. The car is solidly assembled, but everything in the early ones (<06) was extremely problematic &/or cheaply designed or sourced.
Last edited by Barry45RPM; Jun 20, 2012 at 05:23 PM.
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2009 SL550 Roadster Diamond White, 2008 CLK550 Coupe Obsidian Black
Junior Member
Joined: Apr 2012
Posts: 29
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2007 E550 4matic
I replaced my driver's-side sender unit today. I tend to suspect that getting MB to admit fault and pay for all W211 fuel leaks is going to take a long time and I really didn't want to live with the fuel smell till that happens.
It's not a huge job to perform and took me slightly more than one hour. I'd say the special locking ring tool is almost a must--I can't imagine getting those off without the tool. I also replaced the seals on both units--the old seals were white, the new seals were green.
I'll conduct a postmortem on the old sender unit to see what really failed.
I've filled the tank and I no longer smell fuel. Hopefully this will remain fixed for a while.
It's not a huge job to perform and took me slightly more than one hour. I'd say the special locking ring tool is almost a must--I can't imagine getting those off without the tool. I also replaced the seals on both units--the old seals were white, the new seals were green.
I'll conduct a postmortem on the old sender unit to see what really failed.
I've filled the tank and I no longer smell fuel. Hopefully this will remain fixed for a while.
Newbie
Joined: Jun 2012
Posts: 3
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mercedes benz CLS
the best way is always check the fuel sending unit if it is still in good condition, sometimes the fuel runs out fast but when you really check it, it still full or still have more fuel. Or sometimes the problem is there is a leak that's a very dangerous matter.
Newbie
Joined: Jun 2012
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Mercedes E-350
You make it sound easy. Was it difficult to access the unit? I'm going to ask the MB dealer to check out the one on a used car tomorrow and want to sound somewhat intelligient regarding the amount effort it should take them to do. Thanks.
