Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 Mercedes-Benz E320 owners, lightly cleaned up (personal details are redacted by NHTSA).
I filled the gas tank full and on pulling in the garage could smell a strong smell of gasoline... Went to get my oil change the next day and the gentleman mentioned he could smell gas coming from my car at valvoline oil change.... Very strong smell in the interior of the car as well as when walking around the outside of the car you could smell a strong smell of gas... The gentleman from valvoline looked under the car and said there's some type of cover that goes underneath the gas tank itself and put his finger into it and could touch gasoline on his hand... I just went onto the internet and read many many complaints of the same thing with this type of car lawsuits have been filed... In those complaints the people that brought their car to dealership said that it was very expensive to remedy and that there should have been a recall... …
Tl* the contact owns a 2004 Mercedes-Benz E320. The contact stated that a fuel odor was perceived inside and outside the vehicle without warning. The vehicle was taken to the American service center dealer [phone], located at 624 s glebe rd, arlington, va 22204) where it was diagnosed that a canister valve and purge valve shut off and caused fuel to leak in the rear of the vehicle. Technician advised that the valves and the fuel pump needed to be replaced. The contact was told that there was no recall. The manufacturer was not made aware of the failure. The vehicle was not repaired. The contact referenced NHTSA action number: ea13003 (fuel system, gasoline). The failure mileage was approximately 140,000. The VIN was not available.
Driver is experiencing a heavy odor of gasoline after fill up. Vehicle is not overfilled/topped off. Vehicle was sitting inside garage when owner noticed a heavy fuel odor and notified fire department to investigate. Per recommendations of fire department, keep vehicle out of garage until issue could be inspected by a qualified mechanic. Mechanic inspected fuel system and found fuel leak under rear seats near fuel pump/sending unit. Mercedes Benz refuses repair issue saying it is not a safety issue. Gasoline fumes/vapors are especially heavy inside a single car garage, and if a ignition source is introduced it could become fatal.
Tl* the contact owns a 2004 Mercedes-Benz E320. When the fuel tank was full, a strong odor of fuel was present inside the vehicle and in the garage. Mercedes-Benz of fairfield (165 commerce drive, fairfield, ct 06825) stated that the fuel tank seal May be faulty. The contact purchased a fuel tank seal and had it installed by an independent mechanic. The vehicle was not taken to the dealer for diagnostic testing. The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 82,000.
Customer complains of fuel smell outside of vehicle on approach. Upon entering the vehicle the smell is unbearable and causes nausea when driving. Inspected the vehicle and found the left side (driver's) fuel pump seal is leaking causing fuel to puddle and saturate inspection plate. The fuel wicks past inspection plate gasket and into the passenger compartment saturating the area directly under the rear seat. Replaced fuel pump module with seal (gasket) as well as gasket on right (passenger) side.
Tl contact owns a 2004 Mercedes Benz E320. The contact stated while the vehicle was parked, a strong fuel odor emitted outside of the vehicle. After inspecting the vehicle, the contact noticed that a small puddle of fuel leaked from the fuel tank onto the ground. The vehicle was not diagnosed or repaired. The manufacturer was notified of the issue. The approximate failure mileage was 108,000.
Heavy fuel odor emanating from vehicle. Vehicle and possibly structures could catch fire if fuel is leaking and an ignition source is introduced. Only viable reason why fuel odor is present is either the fuel tank is leaking at a location or the vent has failed. Vehicle fuel odor is especially strong if vehicle was filled up recently but is present 24/7.
Tl* the contact owns a 2004 Mercedes-Benz E320. After refueling the vehicle, the contact noticed a strong odor of fuel. The vehicle was taken to the dealer where the techncian speculated that the vehicle had a fuel leak. The vehicle was not repaired. The manufacturer was notified of the failure. The failure mileage was approximately 127,000.
Tl* the contact owns a 2004 Mercedes Benz E320. The contact stated that there was a strong smell of fuel inside the vehicle. In addition, the contact stated the fuel smell started after refueling the vehicle. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the failure. The failure mileage was 55,000.
Tl* the contact owns a 2004 Mercedes Benz E320. Immediately after refueling the vehicle, a strong persistent odor of fuel permeated from the vehicle. The vehicle was not diagnosed. The dealer and manufacturer were made aware of the failure. The vehicle was not repaired. The failure mileage was 84,000.
NHTSA investigations
Fuel Leakage From The Fuel Tank
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…
Fuel System complaints in other E320 years
Frequently asked questions
How common are fuel system problems on the 2004 Mercedes-Benz E320?
NHTSA has 117 complaints about the fuel & propulsion system of the 2004 Mercedes-Benz E320, 58% of the model year's 203 complaints. The component named most often is delivery › fuel pump (3 mentions).
Is there a recall for 2004 Mercedes-Benz E320 fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2004 Mercedes-Benz E320, though it has 2 recalls for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2004 Mercedes-Benz E320 fuel system problems start?
Half of the complaints with a recorded mileage happened before about 90,000 miles, and 2% before 25,000 miles.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.