austingtir

Due to not being in the USA and being able to take advantage of the warranty repair. I decided to take on the fuel tank issue myself and think I have solved a bunch of issues without spending to much.

1. Replace fuel filter in sender!

2. Repair leaking fuel tank without removing or replacing it (access ports).

3. Replace fuel pumps cheaply via rockauto.


What happens when the fuel pump or sender side leaks via cracks in either the sender or fuel pump white tops. The fuel leaks through these cracks to the outside black surface of the tank and proceeds to warp the outside sealing lip which makes the issue even worse. If you look at our tanks they are double skinned white on inside and black outside. Once fuel gets out side is when it does the damage to the tanks.

My first fix for this as copied from this forum is to fill the top of the sender and pump with jb weld so its much less likely to have the cracking failures. Second I used vice grips to carefully bend the bent opening threaded plastic of the tank back into shape so the new green seals can do their job. Third I insert a glass bowl (with TAPERED sides so it doesnt fall in the tank and the sealing rings can screw down on it) of the correct size into the opening so it holds the opening in shape overnight (I suspect wetting the area you want to move with fuel may also help...) I then refit a new jb weld filled assembly with the new green seals and it should sort the issue provided the warping on the tank opening isnt to horrific.

The fuel filter replacement is as you can see I managed to find a fuel filter (Febi Bilstein 39831) that mostly fits our senders other than one end having a hole that to small which I fixed by drilling it out to just under the suggested size of 10.7mm I drilled/reamed it to 10.5 and it seems to fit nice and snuggly. This brand fuel filter has a plastic reinforcement basket inside it so I think its much less likely to fail or begin to crush like the original filter you can see in my pics was beginning to!

Dublinoh

The USA warranty is a ten year extended warranty (I think), so we will all be in the same no warranty situation soon. I appreciate the post as this may be something I have to face someday. Does anyone know if the replacement tanks are an improved design? Is it just a matter of time before a warranty replacement tank fails? Please give us a long term follow up, I'm curious and hope this will take care of the issue for good.

Hulk

From talking to the tech that did my repair, it is a new part with tank and fuel pumps and filters already in. He said it was a better design. Only time will tell

Rocman8

15 years total from original warranty start date.

Dnasty

I just took my car into a dealer for this very issue and they said they do not honor it. I have a leaking fuel filter and who knows what else strong gas smell etc... the "service advisor" told me it only covers the gas tank itself if it cracks and that in that situation they would only replace the gas tank and none of the components attached to it... which sounds like complete bull to me. I called mbusa who is supposed to have an "executive" call me back on this issue but my experience with mercedes honoring their own warranty is that they tend to be scumbags. The dealer also charged me 180 dollars to tell me this information that I was already aware of. Any suggestions on what to do if mbusa yet again fails to honor their own warranty?

GrumpyDad

I had a similar problem. My right side - fuel pump - was cracked and leaking up top. The first dealer I took my car to said they would not cover it. I went round n round. They said the service manager contacted MBZ and MBZ would not cover it. I pulled my car out of that dealer and called a second one. The first was closer to my house, more convenient, MY MISTAKE.... The second dealer, the dealer my shop works with and buys parts from, said no problem. I gave the service adviser my VIN over the phone, he looked it up in MBZ's database and told me it was all covered (Complete "Fuel Tank Assembly") and new the exact date the 15 extended warranty would expire. OI got them my car the next day and repair was done and returned to me in a day and a half. Key words with this complaint - "Strong fuel smell with a full tank" and "Fuel Pooling on top of the tank". The extended warranty is quite clear. Any part of the fuel tank assembly (pumps, filters, senders, seals, fuel tank etc that would have been covered under the original 4 year warranty, are covered on the 15 year extended warranty. See post #10 https://mbworld.org/forums/w211-amg/...recommend.html . Call around and be persistent!

sjc246

I'm not sure why they would tell you that. The MB bulletin about the warranty extension clearly states that: "The warranty covers the fuel tank, fuel filter/sender, fuel pump, and gaskets (collectively the “Covered Fuel Tank Components”)". I have attached the latest copy of this bulletin. It's most likely just a simple misunderstanding on their part, but given how common a problem this is, it certainly shouldn't be happening (hopefully they're not trying to bill you for the repair and submit a warranty claim at the same time to get paid double). Depending on what model you have, either the defective component (ie. filter module) will be replaced, or, in many cases, the entire tank assembly including all pumps and filters will be replaced. If you PM me your VIN and email address, I can tell you which case applies to you.

If I were you, I would go back and ask to talk to the service manager (not the service adviser), show them a copy of the bulletin, and politely ask for them to repair your car AND refund the $180 they charged you. Let them know that if they will refuse, you will be speaking to MBUSA about the issue. If they do refuse, make sure to follow through with MBUSA because they should definitely be able to help you out with this.

Dnasty

GrumpyDad

Can be a pain. On mine the first dealer ran it as a failed fuel pump - out of warranty. In that case they are correct, a failed fuel pump is out of warranty. In your case they may have run it as a failed fuel filter or regulator - out of warranty. It's all in how they present it or write it. That's why I mentioned " Fuel Smell and Fuel Pooling". That's what the extended warranty/bulletin specifies.
I also had my letter and photos, and went in with my rear seat already removed - made it easy for them. Oh well.... Keep after it.

Dnasty

Well the funny thing is they noted all this in their diagnosis of my car. This is basically what they sent me via email so either this guy just doesn't know anything about the warranty or he's the worlds worst con man.. or is this wording in fact a way to get out of the warranty? . He of course screwed up my reason for bringing the car in as I said it was able to be smelled outside of the vehicle (not in the cabin and not while accelerating). He initially agreed with me as soon as I got out the car as its very pronounced and obvious to anyone around the vehicle.

A. CLIENT REPORT THERE IS A VERY STRONG FUEL
TYPE SMELL COMING INTO THE CABIN OF THE
VEHICLE,ESPECIALLY WHEN ACCELERATING OR ONCE
THE FUEL TANK HAS BEEN FILLED.CHECK AND ADVISE
X
REPLACE FUEL FILTER AND DRAIN TANK. MUST ALSO
REPLACE SEAL ON FUEL PUMP (FUEL FILTER IS
LEAKING)
Fail $1,043.00

w204_racing

Dnasty

Dnasty

Well it was as you guys said all in the wording or atleast that's what the service manager told me. They are now putting a new gas tank (and fuel filter etc.) in the car under warranty. I am not sure if the manager himself did this or my call to mbzusa caused the change in attitude because the dealership called then a couple hours later mbusa called saying they spoke with the dealership and wanted to check with me. Either way they are taking care of it as they should. Thanks for all the input guys.

Redwood415

I got mine done for free and they replaced the whole tank! God Bless America...

redc36

creative steel seems to carry replacement fuel filter:
https://creative-steel.com/shop/03-0...t-fuel-filter/

not sure if its direct fit or not but hopefully someone has tried it.

CDC55AMG

Hello does this fuel tank extended warranty cover the 2006 CLS55 models in addition to the E55s?
Thank you!

StarvingArtist

Yes

StarvingArtist

You might want to read the sticky thread on this before calling the dealer.

CDC55AMG

Thank you very much I will.

Osgee

Ive replaced my filter but my plastic tube where the rubber pipe was very weak and brittle, unfortunately I snapped it while removing the clamp.

I now need a new lid for my filter basket.

The only problem is the new ones ive seen have two plugs and mine has only one. I dont really want to buy new pumps just needed a bew bloody lid!

Would the newer style lid clip on and work? As they orginal plug looks the same just i dont have a wire for the secondary (external level sensor)

God knows what to do 😢