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 2005 Mercedes-Benz E320 owners, lightly cleaned up (personal details are redacted by NHTSA).
The passenger compartment smells like gasoline. This is due to an issue that was already investigated by nhtsa however the warranty that was extended is expired by two years. I just purchased this vehicle used and it is unsafe to drive. It did not smell like gas a few weeks ago when it was purchased. The odor is very strong in the passenger compartment.
Battery light came on so it was charged then reconnected, everything good, turn key to on position everything good, turn key to start and bang! Loud bang and white smoke everywhere, engine continued to smoke for several minutes after explosion, hole in front of engine
In 2015 we started to notice the smell of gasoline following filling the tank with gas. The smell of gasoline is so strong that we had to open our garage doors to vent the fumes. No gasoline was spilled during refueling. There is no visible gas leak on the garage floor. The vehicle is a 2005 Mercedes-Benz E320 with only 44,000 miles. After researching this problem we discovered numerous other owners of this model Mercedes have experienced the same problem. Mercedes has no recall for this fuel fume defect and any repair is not within the original warranty period. NHTSA action #ea13003 summary test & analysis by Mercedes-Benz shows no risks of fire or passenger safety. This is bs as fuel fumes within an enclosed area, such as a garage where a natural gas hot water tank exists, could cause a fire. NHTSA needs to require Mercedes-Benz to recall the vehicles affected by this defect.
8/4/16 vehicle had strong smell of gas inside after fillup. Went away after half full. Noticed recall in online doc's and took to Mercedes of san diego where tank mod, cable harness, bracket, seal ringx2, insulation under seat were replaced no charge under warranty. 6/20/17 vehicle quit when approaching residence. Then wouldn't start but cranked. Same symptoms next day. Towed to mb san diego diagnosed fuel pump components failed $1,000 w/no offer to cover under recall. I further reviewed same internet doc's which show fuel pumps, filters, fuel level senders are covered under mb 15 yr. Unltd miles warranty. Will call service writer in morning to advise they should cover repairs, tow plus rental car while I was researchng.
Tl* the contact owns a 2005 Mercedes Benz E320. The contact stated that the driver of the vehicle was traveling approximately 40 MPH when another vehicle crashed into the rear passenger's side of the vehicle. The vehicle immediately became engulfed in flames. The driver was fatally injured with trauma to the head. The passenger was fatally injured with trauma to the torso and the two rear passengers died from smoke inhalation. The police were on scene and a report was filed. The contact stated that the fuel system May have been the cause of the fire that erupted upon impact. The cause of the fire was not determined. The manufacturer was not made aware of the failure. The approximate failure mileage was 65,000.
I have a 2005 E320 Mercedes Benz. Every time we fill the tank we get a strong gas smell inside the vehicle. After we drive the vehicle for a while with the windows open the smell dissipates. The smell is coming from under the rear seats. I suspect the seal on the gas tank has failed. This is a design flaw that should be taken care of by the manufacture. It is not a normal wear and tear item. My concern is fuel fumes can impair ones driving ability and leaking fuel can create a safety hazard. With the number of complaints that I have come across I feel that there should be a re-call to correct.
Re complaint number 10778442 since the last report the situation has gotten much worse. Initially the gasoline fumes would occur while the tank was more than 1/2 full. Now the fumes are very very strong when the tank is full but remain strong even as the fuel indicator nears the empty mark. This this the only vehicle I own and my family and myself cannot remain in the car for more than a few moments. The fume are overpowering and this is a major health concern wise as well as a chance of fire.
Tl* the contact owns a 2005 Mercedes Benz E320. The contact stated that there was a fuel odor in the vehicle and fuel was accumulating into the fuel access compartment under the rear seat. The vehicle was taken to the dealer where it was diagnosed that the entire fuel tank needed to be replaced. The failure caused electrical wires to be submerged in the fuel. The vehicle had not been repaired. The manufacturer was not notified of the failure. The approximate failure mileage was 140,000.
The fuel pump and/or gasket is leaking gasoline into the area under the back seat on the drivers side. The first time we noticed the problem was on nov 1, 2012, but it has happened several times since then. We can no longer fill the tank to the full position without fuel leaking. We have replaced the fuel gasket, but it has since leaked again. This is a great safety concern to me, and it should be corrected by Mercedes Benz at no cost to me.
Fuel sending unit leaking fuel - strong odor of gasoline. I see that many other w211 style Mercedes Benz owners are complaining about the same thing. I took it into my mechanic and he says that the sending unit is leaking and this has been an going problem with these vehicle. Mercedes needs to recall this for safety reasons and do the right thing. Please add my complaint to the pile of complaints already received by your agency.
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 2005 Mercedes-Benz E320?
NHTSA has 122 complaints about the fuel & propulsion system of the 2005 Mercedes-Benz E320, 53% of the model year's 231 complaints. The component named most often is storage › tank assembly (3 mentions).
Is there a recall for 2005 Mercedes-Benz E320 fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2005 Mercedes-Benz E320, though it has 3 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 2005 Mercedes-Benz E320 fuel system problems start?
Half of the complaints with a recorded mileage happened before about 82,000 miles, and 1% before 25,000 miles.
Is it dangerous?
Owners linked 1 crash, 2 fires and 4 injuries and 4 deaths to fuel & propulsion system problems on this model year. If you notice symptoms, have the car checked before driving further.
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.