Filed my complaint this morning. I my need new fuel senders. I get a strong odor at full tank, as well as stop and go traffic when hot out. I sit in traffic for hours some times and have had other people tell me my car reeks of fuel.

Pretty ****ty design. Does anymore make a different sender? Do the European AMG'S have this same issue?

Pull the rear seat (easy to do) and unscrew those round inspection covers to take a look at the fuel senders/filters below.....

My guess is that you have raw fuel pooled up in those areas.

You can search for my previous posts, I show the whole procedure with photos.

The short-term solution is to clean up the excess fuel and never fill up past 3/4 tank. When the fuel warning light comes on, you can add EXACTLY 10 gallons without causing fuel to leak out through the cracked plastic areas.

I drove my car for over a year playing that 10 gallon fillup game. No smells, but it was a pain on long trips to have such a small fuel reserve.


-G

Already pulled them out, inspected and tightened down everything. No leaks or smells. I'll probably remove everything and fill up this weekend with the panels off. Monitor closely. No stains or residue either.

Recall was done on mine back in 2009. Entire fuel tank was replaced.

To be clear, the "recall" was nothing more than a small metal sleeve inserted into one of the plastic fuel fittings on the sender bodies.... basically a 10 cent part, that didn't solve anything.

The only other thing I've heard that can cause fuel smells is a saturated charcoal canister.... usually caused by overfilling, but it is pretty easy to remove and reasonably inexpensive to replace. Might be worth a look.


-G

Please review this accordingly: Emission Recall Campaign 2008020001

Summary: fuel filter module leaking due to mechanical stress. fuel evaporation through these small cracks may lead to fuel smell

Consequence: Customer complaints of fuel smell.

Contact Mercedes : 1-800-367-6372

http://www-odi.nhtsa.dot.gov/cars/pr...h&summary=true

For more information on the status click link. Looks like it is still in progress with no final determination.

I just wrote up a DIY for my CLS55 in that forum, but It should also apply here to E55's
Here's the link
https://mbworld.org/forums/w219/5581...ml#post6182813

FYI, if anyone is interested, you can hit the documents button at the bottom and see all of the documents / data being discussed by MB, ODI, NTHSA.

Much of MB's engineering responses are redacted for "business confidentiality" reasons. But there is an entire spreadsheet of warranty claims on peer vehicles as well.

Interesting process indeed.

Well looks like I'm going to this party as well.. HG Motorsports just told me my drivers side unit is leaking.. I have a stong gas smell coming from the rear drivers side wheel well, only when the car is turned off however, hmmm.. Second opinion coming from ACG in the next week or so...

Same here... Again. This is the 4th time. 1st time (2007) they did something at the dealer. 2nd time (2009) they replaced the tank bc it was leaking gas all over the garage. Third time, out of warranty and dealer said its on my dime (2012), I had the Indy replace both fuel pumps. Now (2014), gas leaking from both sides.... urgh.

I got hit with a P0456 code this morning. I filled up last night (3/4 tank). No fuel smell this morning but the other night I was heavily fumed inside and outside. I guess I'll be doing the 10 gallon trick for now. I would really love to ditch the OEM stuff and go with an external pump/filter.

Sorry to hear that.....

PLEASE for you new guys who are seeing this issue for the first time, go to the NHTSA website and submit a formal complaint. Last I checked, there are over 250 individual complaints about fuel leaks there and it's getting awfully hard to pretend that this isn't a design-related issue.

At some point NHTSA is going to drop the hammer on MBZ-USA and force them to fix this, but we have to keep logging complaints to keep the pressure on!!


-G

G,

I filed a second complaint today. First one was the first fuel smell when I purchased it. This morning was the first CEL I have had related to the fuel smell. When I said it was bad the other night, I opened the trunk and about passed out.

Ahh, the circle is complete.

Make em pay boys! Im digging out records as we speak.

Nice work MB USA, I have 3 more Audi's in the garage including a new S.

Very Cool. I have paid for 2 fuel sender repairs already.

NHTSA E55 Fuel Leaking from Fuel Tank RECALL INFO
 

http://www-odi.nhtsa.dot.gov/owners/...2J!-1600026731


Date Investigation Opened: MAR 15, 2013
Date Investigation Closed: DEC 19, 2014
NHTSA Action Number: EA13003
Component(s): FUEL SYSTEM, GASOLINE

All Products Associated with this Investigation http://www-odi.nhtsa.dot.gov/owners/...range-down.png

Details http://www-odi.nhtsa.dot.gov/owners/.../orange-up.png

18 Associated Documents http://www-odi.nhtsa.dot.gov/owners/...range-down.png

Manufacturer: Mercedes-Benz USA, LLC.
SUMMARY:

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 unreasonable risk to motor vehicle safety. Additional information concerning this investigation, including a list of the above ODI reports and Vehicle Research and Test Center Report No. VRTC-DCD-3206, can be found at http://www-odi.nhtsa.dot.gov/owners/SearchSafetyIssues (search for EA13-003).

Get your receipts ready gentlemen. Call MBUSA and start requesting full refunds. This is going to cost a fortune!

I usually put in about $20-$25 in gas to avoid the smell. With gas prices a little lower this adds up to more gas. Went into the garage this morning and, "dont light a cigarette" the gas smell was awful. Called my local MB dealer and quoted the service bulletin. They dont call it a "recall" but an extended warranty!
I take mine in Friday morning at 7:30am....fingers crossed it is all covered. Service manager was very friendly and was quick to schedule the appointment. I will report back when I get the news.

It is covered, and it's an extended warranty because they change the parts for the same parts, recall is when it's a newly designed part.

That makes sense.... I just hope to get it fixed and move on. Hate that gas smell and when kids are in the back seat I almost feel a little fear. Thanks for the clarification...

Gas tank leak...Covered under the extended warranty just released. Picking up my car tomorrow. Fingers crossed!

Important Warranty Extension Information
 

https://mbworld.org/forums/e-class-w...-re-tanks.html

MBUSA extending the warranty for fuel tank and components for E-Class and CLS-Class vehicles to 15 years unlimited mileage.
That means reimbursement if you have already paid for related services!

They replaced my gas tank, sending unit, hoses and pump under warranty. 2005 E55. Only cost I had was 1.5 hours extra for an aftermarket exhaust and it taking them the time to get it off.
So happy...filled car up 2 times since and no smell or errors.!!!!

This may be a new one for everyone! I finally got the this horrible fuel leak & smell taking care of at a dealership. The work involved replacing the fuel tank system 211-470-03-00, which I think included the tank & fuel filter/sender. I picked up the E55 AMG "beast" of a car and immediately noticed the fuel smell inside. I rolled down the windows to air & also tried to air out the smell for several days with no luck. I brought the "beast" back to the dealership for an inspection & luckily no fuel leak but they recommended replacing the apparently saturated seat cushion & foam for $623.00. Does it sound like the seat cushion & foam would get compromised? According to the ODI Resume EA 13-003 neither ODI nor Mercedes found this was possible (see the quote below). Please help make some sense out of this seat cushion & foam issue.

"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."

It's common sense the seat and interior area can be affected by fuel and vapors. That cover is sealed but only with some tar gum, which is *not* leak proof. If the fuel is flowing enough it will get into the seat cushion.