2007 MERCEDES BENZ AMG E63 Fuel/propulsion System Problems

My 2007 Mercedes-Benz E63 AMG, which has developed a fuel system defect resulting in a leak. This issue poses a significant safety risk, including the potential for fire and explosion, and is directly related to a known defect that Mercedes-Benz USA has previously acknowledged through an extended warranty campaign.Safety Risk: Fuel system leaks pose an imminent danger, including the potential for fire and explosion, to vehicle occupants and others on the road. Manufacturer Acknowledgment: The warranty extension campaign underscores Mercedes-Benz’s recognition of this defect as a manufacturing issue, Repeat Occurrence: Having experienced this defect in my previous 2005 E500 4MATIC and now my 2007 E63 AMG, it is evident this issue is systemic and not isolated.Ethical and Legal Responsibility: Safety defects do not have an expiration date. Mercedes-Benz has an obligation to address this issue regardless of warranty status.Mercedes-Benz USA recognized the severity of this defect by extending the warranty coverage to 15 years and unlimited mileage for “Covered Fuel Tank Components” in specific models, including the 2003–2009 E-Class (W211). I received a notice in 2015 outlining this warranty extension, which covered the fuel tank, fuel filter/sender, fuel pump, and all related gaskets, seals, and retention rings. Additionally, Mercedes-Benz USA formally notified the U.S. Department of Transportation's National Highway Traffic Safety Administration (NHTSA), specifically the Office of Defects Investigation (ODI), of this extended warranty campaign in 2014. While the ODI concluded that the nature of the leaks "does not appear to present an unreasonable risk to motor vehicle safety," I strongly disagree. Any defect involving fuel system leaks represents a substantial safety hazard, including the potential for fire, explosion, and environmental harm.

VIA REGULAR MAIL AND ONLINE SUBMISSION RE: VIN # [XXX] – Mercedes Benz 2007 E 63 Dear NHTSA – We would like to bring to your attention the failure of the Fort Lauderdale Mercedes Benz dealership to properly honor the repair and replacement of parts and labor covered under a recall for Fuel Tank Components for MODEL 211 (E-Class) years 2003-2009. A copy of the Recall notice which provided for an extension of the Recall thru 01/31/2021 is attached. Also attached please find a recent repair invoice for the respective repairs which should have been repaired under this recall. Mercedes Benz undertook a “partial” repair of the parts covered under this recall and at the time of that repair failed to properly repair all of the parts related to this issue/recall. Instead, they only replaced one fuel tank/fuel pump while the extended warranty coverage was in place and left the issue to materialize/manifest in the remaining fuel pump/tank despite the fact that conditions indicated it would likely fail in the near term at the time of the partial repair. Of further concern is the fact that an active Recall for the exact same item exists and remains active for later model years. Clearly, they have not fixed the cause of failure for this vital car part and continue to place drivers/owners at considerable risk. NHTSA – ODI It is incredulous to me, a 25+ year dedicated Mercedes Benz customer that an experienced dealership would attempt to evade responsibility for such a significant safety recall item. When this issue exists, the smell and fumes of petroleum/gas can be easily smelled from the exterior of the car. If you were to light a cigarette – you would likely cause the car to explode. When this issue existed, the interior cabin of the car would fill with petroleum/gas fumes again placing the driver at considerable risk. Please review the attached documentation and require Mercedes Benz to acknowledge that their half-hearted repair done during the recall INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATIO

I FILLED UP THE GAS, TOOK A SHORT DRIVE HOME, AND PARKED IN THE GARAGE. NEXT DAY, THERE IS A STRONG GASOLINE SMELL IN THE GARAGE AS WELL AS INSIDE THE CAR. THIS HAPPENED WHENEVER I FILLED UP THE GAS SINCE THEN.

Mileage: 64,500

I JUST PURCHASED THE VEHICLE USED FROM A DEALERSHIP. I DROVE THE VEHICLE 2000 MILES HOME AND I PARKED THE CAR IN MY GARAGE. I FILLED THE GAS TANK PRIOR TO PARKING IN MY GARAGE. THE NEXT MORNING I ENTERED MY GARAGE AND SMELLED A STRONG ODOR OF GASOLINE. I COULD SEE GAS UNDERNEATH MY CAR BY THE REAR DRIVERS SIDE WHEEL AND THE ODOR OF GASOLINE WAS SO STRONG MY EYES WERE WATERING AND I COULDN'T BREATH WELL. I OPENED THE GARAGE DOOR AND MOVED THE CAR OUTSIDE(PUSHED IT OUTSIDE TO AVOID AN EXPLOSION). THE ODOR OF GASOLINE IS VERY STRONG BY THE DRIVER'S SIDE REAR COMPARTMENT. I KEEP THE FUEL TANK AT HALF FULL OR LESS TO MINIMIZE THE GASOLINE VAPOROUS SMELL. I BOUGHT THE CAR IN CHICAGO AND DROVE IT HOME TO WASHINGTON STATE. *TR

Mileage: 96,000

WHEN I FILL UP THE FUEL TANK TO FULL, I SMELL A STRONG SCENT OF GASOLINE INSIDE THE CAR. THE FUEL IS LEAKING SOMEWHERE UNTIL I BURN IT DOWN TO ABOUT A 3/4 TANK FULL. *TR

Mileage: 95,000

STRONG FUEL SMELL AFTER FILL UP FOR OVER A YEAR. WAS BROUGHT TO MERCEDES WITH NO FIX. RECENT INSPECTION RESULTED IN FINDING A PUDDLE OF FUEL UNDER THE REAR SEAT ON THE FUEL SENDING UNIT. FURTHER RESEARCH SHOWS THIS IS A ONGOING PROBLEM FOR OTHER E-CLASS AND HAS BEEN REPORTED TO NHTSA, AND CURRENT FIXES IF ANY HAS BEEN FAILING AND EVEN OWNERS HAVING TO PAY OUT OF POCKET FOR SOMETHING MERCEDES SHOULD BE FIXING UNDER WARRANTY DUE TO THIS SERIOUS POTENTIAL SAFETY AND FIRE ISSUE. I HAVE TWO TODDLERS WHO SIT IN THIS CAR EVERYDAY. *TR

Mileage: 90,000

TL* THE CONTACT OWNS A 2007 MERCEDES BENZ E63. THE CONTACT STATED THAT THE VEHICLE EMITTED A FUEL DOOR. THE CONTACT INSPECTED THE VEHICLE AND NOTICED THAT THE FUEL TANK WAS LEAKING EACH TIME IT WAS FILLED BEYOND 3/4. THE VEHICLE WAS TAKEN TO THE DEALER WHO ADVISED THAT THE FUEL TANK NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS MADE AWARE OF THE FAILURE. THE FAILURE MILEAGE WAS 52,890 AND THE CURRENT MILEAGE WAS 61,200. ...UPDATED 05/29/13 *BF UPDATED 06/14/2013 *JS

Mileage: 52,890

I REPORTED TO MY INDEPENDENT MECHANIC A STRONG FUEL SMELL WHEN FILLING THE VEHICLE FULL AND PARKING IT. UPON FURTHER INVESTIGATION, MY MECHANIC DISCOVERED A FUEL LEAK FROM THE DRIVERS SIDE OF THE TANK ONTO THE LEFT EXHAUST WHICH OF COURSE CAN CREATE A FIRE HAZARD. I IMMEDIATELY CONTACTED MY LOCAL MB DEALERSHIP AND SPENT DAYS TRYING TO GET IN TOUCH WITH THE SERVICE MANAGER. FINALLY AFTER CONTACTING THE MB CENTRAL REGION OFFICE, I LEFT A VM AND WAS CONTACTED BY THE SERVICE MANAGER I HAD BEEN TRYING TO GET IN TOUCH WITH. AS OF TODAY 4/8/13, I TOOK THE VEHICLE IN FOR INSPECTION. THEY TOLD ME THAT THE DRIVERS SIDE FUEL SENDING UNIT/PUMP IS LEAKING AND WOULD NEED TO BE REPLACED. I ASKED IF THE CAR WAS SAFE TO DRIVE, THEY REPLIED NO, BUT HAPPILY SENT ME ON MY WAY ANYHOW. THIS PROBLEM LINES UP WITH EVERY OTHER COMPLAINT ABOUT THE MY03-09 W211'S THAT EXHIBIT THIS PROBLEM. I HAVE NOT HAD THE FUEL LEAKING TO THE GROUND AND POOLING UP, BUT THE DEALERSHIP HAS CONFIRMED THAT THE SENDING UNIT IS INDEED LEAKING AND POOLING UP IN THE DEPRESSION WHERE THE SENDING UNIT ATTACHES TO THE TANK, WHICH IS NOW LEAKING ONTO MY DRIVERS SIDE EXHAUST, THUS CREATING POTENTIAL FOR A FIRE HAZARD. NHTSA ACTION NUMBER: EA13003. *TR

Mileage: 46,200

SMELL OF FUEL AFTER PARKING THE CAR AND ENGINE COOL-DOWN. MORE PROMINENT AFTER REFUELING. *TR

Mileage: 81,000

NORMAL FILL UP OF GAS TANK CAUSES FUEL TO LEAK OUT OF TOP OF SENDING UNIT. THE SEAM JUST BELOW THE ELECTRICAL CONNECTION POWERING THE UNITS MOTOR SEEMS TO BE WEAKLY AND/OR IMPROPERLY JOINED, ALLOWING RAW GAS TO LEAK OUT AND POOL INTO A SMALL COMPARTMENT UNDER THE DRIVERS SIDE REAR SEAT. WHEN I PURCHASED CAR USED 14 MONTHS AGO, I NOTICED EXTREME GAS SMELL AFTER 1ST NIGHT IN THE GARAGE. I IMMEDIATLY TOOK VEHICLE BACK TO DEALER WHERE THEY REPLACED SENDING UNIT UNDER 30 DAY WARRENTY. NOW ONLY 14MONTHS LATER AFTER A NORMAL FILL UP AT A GAS STATION AND THEN DRIVING HOME, I NOTICED A VERY STRONG GAS SMELL AS I ENTERED THE GARAGE THE NEXT MORNING. I HAVE FOUND THAT I AM NOT THE ONLY ONE WITH THIS ISSUE. ONLINE RESEARCH LEAD ME TO INFORMATION THAT GAVE ME THE DETAILS NECCESARY TO LOCATE AND REMOVE THE ACCESS PANEL UNDER THE DRIVERS SIDE REAR SEAT. AFTER REMOVING THE TOP ACCESS PANEL UNDER THE SEAT I FOUND (ROUGH ESTIMATE) A MEASURING CUP OF GASOLINE THAT WAS POOLED AROUND THE BASE OF THE SENDING UNIT. SO MUCH FUEL HAD LEAKED THAT IT HAD OVERFLOWED THE PUMPS RECESS AND HAD POOLED INTO THE SURROUNDING (RUBBER/PLASTIC) RECESS THAT SEALS THE TOP OF THE SENDING UNIT FROM THE OUTSIDE. *TR

Mileage: 55,000

AFTER FILLING THE CAR WITH GASOLINE AND PARKING IN MY GARAGE THERE WAS A OVERWHELMING ODOR OF GASOLINE AS WELL AS POOLING LIQUID GASOLINE UNDER THE DRIVER SIDE REAR WHEEL. I'VE OWNED THE CAR LESS THAN A WEEK. *TR

Mileage: 34,000

I HAD JUST PURCHASED THE CAR THE DAY BEFORE (APRIL 28, 2012). WHEN I FILLED THE FUEL TANK, I NOTICE A STRONG SMELL OF GASOLINE. THIS HAS OCCURRED EVERY TIME I FILL THE CAR WITH FUEL. AT FIRST I THOUGHT IT WAS A FUEL INJECTOR LEAKING DOWN AND SOMETHING I WOULD HAVE TO ADDRESS IN THE NEAR FUTURE. HOWEVER, LAST WEEK I WENT TO DRIVE THE CAR AFTER I HAD JUST FILLED THE TANK WITH FUEL. THE CAR WAS IN MY GARAGE AND THE SMELL OF GASOLINE WAS VERY STRONG. I NOTICED A PUDDLE OF FLUID IN FRONT OF THE LEFT REAR TIRE. MY FIRST REACTION WAS IT WAS CONDENSATION FROM THE AIR CONDITIONING SYSTEM. I BENT DOWN TO LOOK AT IT AND THEN I NOTICE A SEPARATE CONDENSATION TAIL COMING FROM THE MIDDLE OF THE CAR. I SAMPLED THE FLUID STREAM FROM THE MIDDLE OF THE CAR AND INDEED IT WAS WATER. HOWEVER WHEN I LOOKED AT THE OTHER PUDDLE, I NOTICE A CONSTANT AND RAPID DRIP COMING FROM THE SHIELD UNDER THE GAS TANK. WHEN I SAMPLED THE PUDDLE IT WAS PURE GASOLINE. THIS WAS MOST DISCONCERTING AS THIS FUEL LEAK IS VERY CLOSE TO THE EXHAUST AND THE BRAKES. EITHER ONE OF WHICH COULD IGNITE THE FUEL. I AM A MECHANICAL ENGINEER WITH CONSIDERABLE AUTO RACING EXPERIENCE, SO I KNOW HOW DANGEROUS THIS CAN BE. I CALLED MERCEDES BENZ OF SUGAR LAND ON MONDAY (11/12/12) AND TALKED TO A SERVICE REPRESENTATIVE. I TOLD HIM OF THE FUEL LEAK AND HE TOLD ME THERE WAS NO REPORTED ISSUES AND NO SERVICE BULLETINS FOR SUCH A PROBLEM. I WAS ALSO TOLD TO BRING THE CAR IN AND THEY WOULD REPAIR IT AT MY EXPENSE. HAVING PAID MY WAY THROUGH MY FIRST DEGREE AS A MECHANIC AS WELL AS DESIGNING RACING EQUIPMENT FOR FORD MOTOR COMPANY, I BELIEVE THIS SHOULD BE COVERED UNDER WARRANTY AS PART OF THE EMISSION SYSTEM. THIS IS OF COURSE SECONDARY AND IN ADDITION TO THE OBVIOUS SAFETY HAZARD THIS CONDITION PRESENTS. *TR

Mileage: 52,746

AFTER FILLING THE FUEL TANK, THE SMELL OF FUEL WAS SUCH TO INDICATE A LEAK. AFTER MANY HOURS THE SMELL IS STILL CONSTANT. *TR

Mileage: 67,500

SIMILAR TO THE COMPLAINTS FILED BY MERCEDES BENZ W211 MEMBERS OWNING 2003 - 2006 E55 AMG'S, MY 2007 W211 E63 AMG IS EXPERIENCING FUEL LEAKING FROM THE FUEL SENDER/PUMP ASSEMBLY UNIT. I NOTICED A DISTINCT GAS ODOR IN MY GARAGE THE MORNING AFTER I FILLED UP WITH GAS. I CHECKED THE FUEL SENDER/PUMP ASSEMBLY AREA AS IS STATED IN MANY FORUMS WHERE OWNERS ARE COMPLAINING ABOUT THIS COMMONLY OCCURRING ISSUE. THERE WAS FUEL PUDDLED IN THE CUP OF THE ASSEMBLY. I REPLACED THE SEAL HOPING THAT IT WOULD CORRECT THE ISSUE BUT IT DID NOT. I FILLED UP AGAIN WITH FUEL ON TUESDAY, AUGUST 14 AND WITHIN MINUTES THERE WAS FUEL PUDDLED AGAIN IN THE ASSEMBLY AREA AND A DISTINCT FUEL SMELL ON THE OUTSIDE OF THE VEHICLE. *TR

Mileage: 61,500

CAR BEGAN SMELLING OF RAW FUEL AFTER BEING FILLED UP. FOUND THAT THE FUEL LEVEL SENDING UNIT WAS LEAKING FUEL OUT OF THE TOP OF THE FUEL TANK. A PUDDLE OF FUEL WAS VISIBLE ON TOP OF THE SENDING UNIT AND WAS LEAKING ONTO THE GROUND. THIS POSED A SIGNIFICANT FIRE RISK AND THE CAR WAS MOVED OUTSIDE. I HAVE CONTACTED MBUSA AND THEY HAVE OFFERED NO HELP, SAYING THIS ISN'T A KNOWN ISSUE. AFTER RESEARCHING THE ISSUE I HAVE FOUND IT IS WIDESPREAD AND AFFECTS MULTIPLE MODELS. WE CAN NO LONGER FILL THE FUEL TANK WITHOUT HAVING A PUDDLE OF FUEL LEFT UNDER THE CAR. *TR

Mileage: 48,000