Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2003 Mercedes-Benz E500 owners, lightly cleaned up (personal details are redacted by NHTSA).
My vehicle started puttering and finally shut off. I had it towed to the nearest Mercedes Benz shop located on independence drive in charlotte. After the diagnostic, I was told that the fuel pump was bad. I informed the service advisor colton and the service manager todd about the extended warranty on the components of the fuel system. I was denied warranty coverage because they stated that the fuel tank had to be cracked before they would honor the warranty. To my understanding if the item is a part of the fuel system components, it should be covered for the warranty. They refused to satisfy the warranty and I ended up not authorizing the repairs. Now because Mercedes will not repair the covered part, I have to take it to another repair shop to have it fixed. …
This vehicle has a very strong gasoline smell after I fill the tank. This smell is concentrated on the driver side by the rear wheel. I do not have the money to repair or diagnose the vehicle. Although, Mercedes has issued an extended warranty to 15 years unlimited miles for "covered fuel tank components". The Mercedes dealerships are not able to tell me what the severity or the specific reason for my fuel leak/smell without paying a large diagnostic fee/ w no guarantee of warrantied service. I would like them to share specific information about this problem with me without charging diagnostic fee.
I have had this problem for a while now. When I fill up my fuel tank there is a drastic smell of gas. I believe this is a safety issue. I had to leave my car out on the street in fear my water heater when igniting would set off a explosion. I am sure mb knows of this situation since I have seen numerous remarks and instances on just this subject. I would hope that mb will address this problem. I took it to the dealer and indeed they said that the fuel sending unit has a crack on top allowing the fuel to leak when filled up to the full mark. Thank you advance in reporting this to Mercedes.
While the vehicle was on the highway the car lost power. Pulled over for visual inspection, noticed the fuel was leaking rapidly. Immediately shut off the car. Had vehicle towed to local Mercedes Benz dealership. Dealer verified the tank was leaking.
Shortly after filling the fuel tank, I smell gas fumes towards the back of the car behind drive side outside. There is no fuel leaks that drop on the car and also there is not fuel leaks under the hood of the engine neither.
Fuel fumes were detected during routine maintenance at an authorized Mercedes Benz repair facility. Investigation revealed fuel pooling on top of the fuel filter with integrated fuel pressure regulator. The original equipment defective part number is 3114704094 and has since been superseded. It was determined that there was a leak due to a crack in the plastic assembly. The authorized Mercedes Benz mechanic identified the problem as to similar to the one that resulted in Mercedes Benz voluntary emissions recall campaign #2008-020001. Vehicles included in the recall were model year 2003-2006 e class and 2006 cls-class vehicles. After contacting Mercedes Benz customer service about the problem they stated the recall only applied to the amg version of e class vehicles and my VIN number was not included in the recall. …
"Takata recall" each year it fails the emmission test the failed code is po456. I had an EVAP system test ran they said it was a problem with the purge valve, eval hose, and the filler neck. (leaks). In my own words, the engine comes on and off, the computer is indicating that the truck is open when it is not, the seatbelt tighten up and makes a clicking noise while I'm driving, and sometimes I can't get out of the car it locks me inand I have to push the unlock button on the dash, and the alarm comes on whenever! And the tire pressure indicator stays on and we recently had new tires put on. We had it balanced and an alignment done as well. Other than that the car is still driving well. I thought Benz was one of the best vehicles but I'm not so sure about that now with these concerns! These things happen when in motion except for the alarm going off. …
As reported by many Mercedes owners, our Mercedes E500 has begun the dreaded leaking fuel pump and sending unit. Upon lifting the backseat and tank covers gas is pooling and leaking all over the top of the tank and onto the ground from these assemblies. These part appears defective and not suited to be overlooked by ntsb. Unfortunately my dealer stated there is not a formal recall yet on these parts, but has heard about the problem many times. What does concern me is there was a recall on the e55 model, but in doing the research just as many E500 owners out there are experiencing the same problems. Please give this high consideration for a recall or further investigation. The well being of owners and drivers is not worth the risk and financial obligations that May occur from a recall. Thank you for your time.
Tl* the contact owns a 2003 Mercedes Benz E500. While parked, the contact noticed a fuel smell inside the vehicle. The check engine warning light illuminated on the instrument panel intermittently. There was also a warning message on the instrument panel that advised to check the filler cap. The vehicle was taken to the dealer for diagnostic testing. The technician stated that the fuel filler cap would have to be replaced. After the repair, the contact continued to notice the strong fuel smell in and around the vehicle. There was an investigation open under NHTSA action number: pe12001 (fuel system, gasoline:storage:tank assembly fuel system, gasoline:delivery:fuel pump) that could have been related to the failure. The vehicle was not repaired. The approximate failure mileage was 120,000.
Strong smell of gasoline every time I fill up and until I drive about 50 miles. I was told by a german auto repair shop that it is a cracked gas tank and that this is a systemic problem with Mercedes e-class models from 2003-2005. The smell appears to be emanating from the rear passenger driver's side. I have also been told there was a recall for this exact issue in europe and asia but that Mercedes never issued a recall in the us for this issue despite being extremely pervasive. I drive my children in this car and I am increasingly concerned about this dangerous situation. The repair price I was quoted was about $2400. This seems like it should be a Mercedes problem, not a consumer problem. Nobody should expect their gas tank to crack at any point!
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 E500 years
Frequently asked questions
How common are fuel system problems on the 2003 Mercedes-Benz E500?
NHTSA has 41 complaints about the fuel & propulsion system of the 2003 Mercedes-Benz E500, 33% of the model year's 125 complaints.
Is there a recall for 2003 Mercedes-Benz E500 fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2003 Mercedes-Benz E500, 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 2003 Mercedes-Benz E500 fuel system problems start?
Half of the complaints with a recorded mileage happened before about 96,000 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.