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 E500 owners, lightly cleaned up (personal details are redacted by NHTSA).
The contact owns a 2004 Mercedes-Benz E500. The contact stated while driving 55 MPH, there was an abnormally strong fuel odor inside the vehicle. The contact stated that upon making a stop, he noticed fuel leaking onto the driver's side rear wheel. The vehicle was taken to an independent mechanic where it was diagnosed that the failure was associated with an unknown recall for the fuel tank. The dealer was notified of the failure and informed the contact that the vehicle was out of warranty. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was approximately 71,000.
the car has smelled like gas from the minute i received it. the previous owner told me that mercedes had quoted 5 grand to fix it so i would only put half a tank in at a time. turns out there was a warranty on it but has since expired. why wasn't it fixed for free when the previous owner brought it? this is very dangerous and can cause an explosion. the warranty should have been fixed rather than quoted and seems very greedy to not disclose that information but instead giving a quote. i have lung and heart problems and this is a definite safety issue that needs to be corrected regardless of the age of the car also brought it to dealership scared and they told me too bad it's been too long. how is a gas leak an ok thing to dismiss?????? i have been trying to get this fixed for years and this is my 2nd attempt for a recall with no response at all
I am submitting this complaint regarding a suspected safety-related defect involving the fuel system of my Mercedes-Benz vehicle. I have experienced a persistent gasoline odor originating from the vehicle. The presence of fuel odor is not a normal operating condition and reasonably indicates a potential failure involving the fuel tank, fuel lines, or related fuel system components. Fuel vapors present a known fire and explosion hazard and constitute a safety risk to vehicle occupants, surrounding vehicles, and property. This condition was not present prior to the issue and has persisted despite inspection. I reported this concern to Mercedes-Benz USA and referenced that fuel odor and fuel tank-related defects have been documented in other Mercedes-Benz vehicles. …
Approximately in March 2026, I started noticing a very strong gasoline odor coming from my 2004 Mercedes-Benz E 500 4-matic with original miles approximately 56,300. The fuel odor always got stronger whenever I would fill up the gas tank. The history on my car is such that it has always been garage kept. The gasoline odor coming from my car started getting stronger and stronger while in my garage. On Memorial Day 2026 I called HQ, Mercedes Benz and told them about the gas odor coming from my car. After the call ended I decided that the car needed to be towed to the nearest Mercedes Benz service center. I considered that the gas order to be very dangerous so I parked my car in the driveway. Once parked in my driveway, there was no longer a gasoline order in my garage. …
Benz E500/55K miles. I have had two major safety issues with the car. One being fuel tank related and the second sbc pump failure while driving. On the first, too little too late, so many years after the incident and purchase of the car, Mercedes Benz has sent a letter covering the repair and parts for 15 years. I think that in itself is an offense and a crime. On the second issue, sbc pump Mercedes Benz refused to give me in detail the effect of failing sbc pump on other parts of the car or the effect of failed sbc pump. More importantly, service managers are telling customers that they are expecting all models equipped with sbc pump to come to the shop. Now that the 10 years is up in most cars and out of warranty.that is a scam when the dealer knows all these customers will come to the shop (because it cannot be fixed in any auto shop) thereby taking advantage of a safety issue. …
Vehicle has a recall on replacement of fuel tank. Mercedes Benz dealer did not want to honor the recall. When I fill car up with gas it leaks out of the tank and on the ground. Mercedes-Benz dealer said I missed the time for the recall. I went to the dealership before the recall ended in 2019 spoke with the service advisor at the mckinney Mercedes-Benz dealership and I informed him the car was not drivable due to the braking system failure call the spc hydraulic pump. Turns out that is also a recall that is widely known.at that time the car was not drivable and then the pandemic hit so there was no need to take it up there at the time due to covid. Mercedes Benz should honor this since this is a safety issue that could lead to a deadly situation if not addressed. They have been deceptive by marking this is an extended warranty issue and not a safety recall issue. …
Tl* the contact owns a 2004 Mercedes Benz E500. The contact stated that while driving approximately 55 MPH, the brake pedal was engaged and failed to respond as the brake system warning light illuminated. The contact was able to avoid an accident. The vehicle was taken to a dealer where it was diagnosed that the sbc unit needed to replaced. The vehicle was not repaired. On another occasion, the contact stated that while driving at a various speeds, a fuel odor emitted inside the vehicle. The vehicle was taken to a dealer where it was diagnosed that the fuel tank was fractured and needed to be replaced. The vehicle was repaired two separate times however, the failure recurred. The vehicle was taken back to the dealer where it was diagnosed that the reserve tank needed to be replaced. The vehicle was repaired but the failure recurred. The manufacturer was notified of the failure. …
I purchased my car used at 132000 miles. This was a pre existing condition that dealer didn't mention anything about, because the next day I filled the tank as it was sold to me with less than 1/4 tank, now I know why, I got a very strong odor of gas that filled my garage and smelled inside the car as well. This happens every time I fill the tank. It also sets a check engine light. Dealership I purchased the car from (not a Mercedes Benz dealership) refuses any responsibility for the problem. Check engine light code is "evaporative emission leak detected (small leak)". Also because of the issue my gas light will randomly start blinking and when I accelerate the center display beeps lights up red and said check fuel cap. Fuel cap is fine, I think it's related to the leak.
Tl* the contact owns a 2004 Mercedes-Benz E500. While the vehicle was being refueled, the contact became aware of a fuel leak. The contact stated that there was an abnormal odor detected outside of the vehicle. The contact stated that the the instrument cluster was red and the check engine warning light was illuminated. The vehicle was taken to Mercedes-Benz of goldens bridge 321 ny-22, goldens bridge, ny 10526, [phone] to be diagnosed. A fuel leak was confirmed however, the vehicle was not repaired. The manufacturer was not contacted or informed of the failure. The failure mileage was 180,000.
I felled my car up with gas at lunch 12 noon and when I got off work at 5 pm the gas fumes were so strong I could breathe in my car. I tuck it to south bay Mercedes Benz and was told that the gas tank has a leak and the gas had leaked in to the cabin behind the back set of my car and that the repairs would be covered by the warranty. It's been over 2 weeks and they have no eta on when my car will be fixed. I have a loner but I check online and found that there are a lot of people with this same problem.
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 2004 Mercedes-Benz E500?
NHTSA has 84 complaints about the fuel & propulsion system of the 2004 Mercedes-Benz E500, 59% of the model year's 142 complaints. The component named most often is storage › tank assembly (2 mentions).
Is there a recall for 2004 Mercedes-Benz E500 fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2004 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 2004 Mercedes-Benz E500 fuel system problems start?
Half of the complaints with a recorded mileage happened before about 90,000 miles, and 3% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 1 fire and 1 injury 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.