2004 Mercedes-Benz AMG E55

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 gasoline fuel both inside and outside of their vehicle, particularly after refilling the fuel tank.Many of the complainants noted that the odor subsided or went away after driving some distance thereby lowering the fuel level in the tank.Other owners reported they would only fill the tank to about three quarters full to avoid the odor altogether.Some complainants alleged fuel leaked from the fuel filter/sender, located on the top of the fuel tank on the driver's side, and collected on top of the tank.There were also allegations that the fuel leaks were associated with an Emissions Recall Campaign (No. 2008020001) conducted by Mercedes-Benz USA, LLC (Mercedes) in 2008 on MY 2003-2006 E-Class and CLS-Class AMG models.The issue in the recall involved small cracks in the pressurized outlet fitting of the fuel filter/sender.AMG vehicles are high performance models that operate at higher fuel pressure and use a different fuel filter/sender and fuel pump than non-AMG models.Information on Recall No. 2008020001 is available from the U.S. Environmental Protection Agency (EPA) website at www.EPA.gov.ODI's investigation found various leak sources that are unrelated to the outlet fitting cited in the EPA recall campaign.Through interviews with complainants, field inspections of complaint vehicles, and the collection and laboratory analysis of failed parts, three identifiable leak sources were found.The component parts and areas of the leaks involve the On-Board Diagnostic fuel tank pressure sensor (located on top of the fuel filter/sender), the outlet of the centrally mounted fuel tank fuel filling limiter valve, and the top of the fuel pump. These areas of leakage are located at the top of the fuel tank in unpressurized parts of the fuel system. When the tank is full, fuel can slowly weep/seep from micro-cracks in these components and may collect in cavities on top of the filter/sender, pump, or tank.Contrary to complainant's allegations that fuel entered the inside of their vehicle under the rear seat bench, neither ODI nor Mercedes found a plausible way for this to occur.The fuel tank is located outside of the passenger compartment, attached to the underside of the vehicle.The service access ports for the fuel filter/sender (driver's side) and fuel pump (passenger's side) are located under the rear seat bench, covered by a steel plate, sealed and bolted to the vehicle floor.When technicians service the fuel filter/sender, which has a regularly scheduled 60,000 mile service interval, and/or the fuel pump, the work is performed from inside the vehicle by working through the access ports.By letter dated September 4, 2014, Mercedes has notified the agency that it will extend the original warranty coverage to 15 years and unlimited mileage on Covered Fuel Tank Components in E-Class vehicles in MY 2003-2009 and CLS-Class vehicles in MY 2006-2011.The covered fuel tank components for the warranty extension include the fuel tank, fuel filter/sender, fuel pump, and all related gaskets/seals and retention rings.ODI is closing this investigation based on the manufacturer's extend warranty of the affected fuel system components and in consideration that the nature of the leaks does not appear to present an un

The Office of Defects Investigation (ODI) opened this investigation based on 20 consumer reports.All of the vehicles were E55 AMG models and the complainants alleged fuel leaks or a strong odor of gasoline both inside and outside of their vehicle, particularly after refueling.Some complainants alleged that the leaks may be related to a 2008 Mercedes Benz emission recall (Campaign No. 2008020001) on the fuel filter module. This recall pertained to model years 2003-2006 E and CLS AMG models only.These AMG models use a different fuel pump and fuel filter module than the non-AMG E-class, however, they share other fuel system components, including the fuel tank.Since opening the investigation ODI has received an additional 350 reports relevant to this investigation.Of those reports, 116 reports are on the E55 AMG model.The remaining 234 reports are on other E-class models (i.e., E320, E350, E500, E550 and E63) which are now included in the scope of EA13-003.The investigation has been upgraded to Engineering Analysis, EA13-003, for further study.The ODI reports cited above can be reviewed at www-odi.nhtsa.dot.gov/owners/SearchNHTSAID under the identification (ODI) numbers cited on the following page.

The contact owns a 2004 Mercedes-Benz AMG E55. The contact stated while driving at various speeds, the suspension of the vehicle lowered intermittently. A message advising to stop the vehicle due to low air ride suspension was displayed. The contact stated that the air ride suspension would no longer rise upon starting the vehicle. Additionally, the contact stated that the front passenger’s side seat belt was loosened. The contact stated upon taking the vehicle for State Inspection, she was informed that the air ride suspension system had failed. The dealer and the manufacturer were not notified of the failure. The vehicle was not diagnosed or repaired. The failure mileage was approximately 200,000.

NHTSA ID

11503669

Incident

Jan 25, 2018

Mileage

200,000 mi

The contact owns a 2004 Mercedes-Benz E55. The contact stated that upon placing fuel into the gas tank, a strong gasoline odor began to emit from the vehicle. Upon inspection, the contact removed the rear seat and saw that fuel had leaked from the fuel pumps. The contact reached out to the manufacturer through the manufacturer’s website and his request to repair the vehicle was denied. The contact wrote a letter to the manufacturer and the manufacturer denied the repair a second time. The contact stated that the same failure occurred back in 2008 and that the vehicle was repaired under a manufacturer’s recall. The vehicle was not repaired. The failure mileage was approximately 111,000.

NHTSA ID

11433603

Incident

Sep 6, 2021

Mileage

111,000 mi

When the vehicle is has a full tank of gas, there are heavy fumes of gasoline in the interior of the car. It appears to be the fuel pumps that are underneath the rear seats, leaking fuel on top, next to the the wiring. It is a hazard for fumes and possibly a fire

NHTSA ID

11428180

Incident

May 11, 2020

STRONG GASOLINE ODOR IN THE BACK OF THE CAR AFTER FILLING UP THE TANK. DEALERSHIP CONFIRMED THAT THE TANK NEEDS TO BE REPLACED. THIS ISSUE WAS COVERED AT SOME POINT BUT WAS NEVER DONE TO THIS SPECIFIC CAR VRTC-DCD-3206. I PURCHASED THE CAR A FEW WEEKS AGO AND WAS TOLD BY MB THAT THE PREVIOUS OWNER REFUSED TO DO THE FIX/SERVICE. THE PROBLEM IS STILL THERE THE CABIN HAS AN INCREDIBLY STRONG ODOR OF GASOLINE. IF THE FIX WAS OFFERED AT SOME POINT AND WAS NEVER DONE, WHY CANT THEY PERFORM IT NOW? QUOTE FOR FIX ATTACHED

NHTSA ID

11364187

Incident

Oct 2, 2020

Mileage

148,000 mi

GAS LEAK, THERE A STRONG GAS SMELL

NHTSA ID

11343092

Incident

Aug 3, 2020

Mileage

95,000 mi

SMELL OF STRONG GAS ODOR. RECALL EXPIRED LESS THEN ONE YEAR AGO SO MERCEDES WONT FIX IT. WHY IS THERE A CUT OFF DATE TO A POTENTIALLY DANGEROUS SITUATION? *TR

NHTSA ID

11328300

Incident

May 22, 2020

Mileage

110,000 mi

VERY STRONG FUEL ODOR WHEN HALF TANK OR MORE OF GAS. CANNOT PARK IN GARAGE OR WILL SMELL ENTIRE GARAGE WITH FUEL ODOR. ALSO HAD THIS PROBLEM WITH MY PREVIOUS CAR WHICH WAS A 2004 MERCEDES E500.

NHTSA ID

11319169

Incident

Mar 17, 2020

Mileage

110,500 mi

STRONG GAS SMELL INSIDE AND OUTSIDE. CHECK ENGINE CAME ON AND GAVE ME A CODE P0456. PLESSE ADVISE!

NHTSA ID

11222839

Incident

Jun 12, 2019

Mileage

120,000 mi

Complaint Repeat workshop visit for vehicle vibration while braking from 60MPH. NOTE: Although the symptom is similar to a tire or wheel vibration, it is usually readily noticeable that it is distinctly different if it happens at all times or only while braking. Cause Although the cause of the vibration is most likely due to excessive lateral runout on the rotor or hub/wheel bearing, the system as a whole needs to be checked for other possible contributors. 1. Prior collision damage. 2. Excessive vehicle sitting times without rotating components. 3. Wheel bearing/hub lateral runout. 4. Wheel mating interface has been overtightened (did not follow WIS torque procedures). 5. Mating interfaces have been excessively modified (painted, gouged, bent, etc...). Remedy Read through the entire attached worksheet prior to performing. After performing, please review the final page and perform work accordingly. NOTE: This document is not pre‑authorization or otherwise dealing with warranty. This is intended for diagnostic purposes only. If there are any questions on how to proceed OR The work sheet has been performed and the vehicle has returned with the same concern. Please perform the measurements as seen in the worksheet again and open a TIPS case to the Body, Chassis, and Entertainment team.

Complaint Clanking noise from the area of the speakers in the doors. Cause Under analysis. Remedy To narrow down the cause, first of all remove the door trim. • If the noise continues to occur even with the door trim removed, then continue the diagnosis working towards the speaker and if necessary, create a TIPS case with an informative video as an attachment. Note: Please refer to this document in the warranty claim and, once diagnosis is completed, select the damage code depending on the component part that is causing the issue. • If the noise stops when the door trim is removed, please proceed in accordance with LI72.10‑P‑067691. Information: In this case, do not use a damage code for the speakers in the warranty claim!

Complaint Noises/ squealing from the service brake in various driving situations and ambient conditions. Cause Frictional vibrations Remedy The intent of this document is to reduce noise from high performance AMG brakes. AMG brakes are designed for performance under high load and in certain scenarios, can emit noise. Some scenarios are normal and some are induced by driving style like those listed below: • Driving style such as two footed driving where the pad might be in constant contact with the rotor. • Brake pressure and application style (stop‑and‑go traffic with consistent light brake pressure “riding brakes” where the brakes cannot cool sufficiently between applications). This can cause the brake pads to glaze and have a smooth/glassy surface which can induce noise. • When ambient temperatures rise during summer peak and during cooling and cold winter months. 1. Beginning Diagnostics: a) Check whether the complaint can be reproduced and at which axle or side the noises occur (ideally together with the customer while driving). b) Check the affected system for component wear, mechanical damage or localized overheating damage. Replace damaged components as necessary. c) Assess condition of brake rotors and pads per WIS and visually (i.e. long periods of stagnation, etc...). d) Clean brake components free of brake dust and debris. d) Secure vehicle on a lift. 1. Start the engine and depress the brake pedal 3‑4 times. 2. Check each wheel to see if they turn freely by hand. 3. If a wheel is not turning freely by hand, this needs to be addressed prior to re‑assessing the noise concern. e) Check whether, apart from this document, an additional document exists for the specific model in question, and if so, work through it and then continue. 2. Specific Axle Work: NOTE: If the brake pad has a metal backing plate, there is no need to affix the adhesive film. Continue with applying chamfer and Molykote as instructed below. IMPORTANT: Be absolutely certain to not allow paste between friction surfaces of the pad and disc! a) If the noises are coming from the front axle. 1. Remove brake linings of front axle. 2. Clean all contact points on brake lining backing plate, including the brake lining guide pins and brake caliper/carrier. 3. Clean bonding surface (where pistons contact back of brake pad). Apply adhesive film to the backplate of the piston‑side brake lining where the piston contacts the pad backing plate. See picture "Adhesive and Paste Application Area". 4. Be sure to remove both brown paper backing sides of the adhesive film, it is double sided adhesive film. 5. If adhesive is already installed on backing plate where pistons contact the back of the pad, you may gently scrape off and re‑apply a new adhesive or Molykote. Must not apply the Molykote on top of the adhesive. 6. Chamfer edges (gently round off sharp leading edges) on brake pads. Some pads have vertical grooves, these can be gently chamfered with a triangular file as well. See picture "Chamfering Technique". 7. Apply Molykote to the sides of the backing plate. See picture "Adhesive and Paste Application Area". 8. After installing the brake linings, actuate the brake for 30 seconds. b) If the noises are coming from the rear axle. 1. Remove brake pads of rear axle. 2. Clean all contact points on brake lining backing plate and brake caliper /carrier. 3. Clean bonding surface (where pistons contact back of brake pad). Apply adhesive film to the backplate of the piston‑side brake lining. 4. Chamfer edges (round off sharp leading edges) on brake pads. See picture "Chamfering Technique". 5. Grease contact points (red areas on attachment "Rear Pad Grease Area") between brake lining and guide of brake caliper with Molykote. 3. Brake Bedding Process: a) Before trip, the mileage incurred must be clarified with the customer (approx. 30 miles). b) Select a suitable route so speeds of approximately 65 MPH can be achieved. c) If the vehicle is an AMG P3 Hybrid, switch off

Complaint Clanking noise from the area of the speakers in the doors. Cause Under analysis. Remedy To narrow down the cause, first of all remove the door trim. • If the noise continues to occur even with the door trim removed, then continue the diagnosis working towards the speaker and if necessary, create a TIPS case with an informative video as an attachment. Information: Please refer to this document in the warranty claim and, after completing diagnosis, select the damage code corresponding to the component part that caused the problem. • If the noise stops when the door trim is removed, please proceed in accordance with LI72.10-P-067691. Information: In this case, do not use a damage code for the speakers in the warranty claim!

Single throttle lift-off clunking noise from the side shaft when moving off (audible at the outboard end). The noise is heard once in each instance when changing direction of travel. Note: Sound file in attachment Cause If the complaint is eliminated by experimentally loosening the outboard collar nut (by 1 turn), the problem is due to cracking of the microweld between the wheel bearing inner race and the joint housing of the side shaft. Note: The collar nut must always be replaced after being loosened. See also LI33.20-P-078406 Remedy Coat contact surface of side shaft with wheel bearing with Molykote paint. To do this, proceed as follows: 1. Remove side shafts 2. Clean contact surface A (see image file in attachment "Outer joint housing before") before coating with Molykote, using "spirit" (free of dust and grease) 3. Coat contact surface A (see image file in attachment "Outer joint housing after") with Molykote and leave to dry for "one hour" in removed condition 4. Reinstall side shafts Note: Before using the antifriction coating (Molykote), stir it or shake it thoroughly for (at least 1 minute).

Complaint There are several types of complaint about noises or poor windshield wiper wiping performance: A: Wiper blades squeaking, chattering, shuddering B: The windshield is not wiped completely (streaking) C: During the downward movement water is pulled back onto the windshield from the A-pillar (Figure 1) D: After windshield cleaning, water keeps spraying onto the windshield for several wipe cycles (Figure 2) A1: The windshield and wiper blades are contaminated with residues from car washing facilities, identifiable by the water beading. The resulting differences in the friction values between the wiper blades and the windshield can excite the wiper blades to vibrate. Note: It is mostly wax residue from the washer system, but also water-repellent nano-particle coating for paint and/or silicone-based washer fluid, that could cause this problem. A partially dry windshield also has different friction values, which can likewise result in squeaking of the wiper blades A2: The wiper blades are worn by mechanical damage (wiper lip damaged by ice or insect debris, or deformed by long periods of disuse). A3: Incorrect angle of incidence of the wiper arms to the windshield. Because of this, the rubber lip of the wiper blade may not flip over at the reversal point. Cause B: B1: Wax/ dirt residues on the windshield B2: Wiper blades deformed or worn B3: Downforce of wiper arm not OK (Figure 3) Cause C: Water is pulled back onto the windshield by the differential pressure created as the wiper arm moves downwards. Cause D: Washer water collects in the fastening of the wiper blade and is blown onto the windshield by the airstream over several wipe cycles. Note and supporting information: Wiper blades are wear parts which, even when "not used" for long periods (kept in park position), may become permanently deformed and damaged. Further stresses on the rubber wiper blade arise due to various environmental influences which progressively change the effectiveness of the rubber wiper blade and accelerate the aging process. Due to the natural aging process and wear, the wiper blades should be replaced twice a year, preferably in Spring and Fall (see operator's manual). Remedy Remedy A: A1: Cleaning entire windshield with A 000 986 40 71. A2: Checking water's flow behavior after windshield has been cleaned (see Video 1). If, after cleaning, there are still areas with water beading, then the cleaning process must be carried out again until a rejection reaction is no longer present. • Note: On the vehicle in the video (Video 1), water still beads on the bottom left of the windshield. The windshield is still not properly clean, even though it appears to be clean. The windshield is only properly clean when there are no more areas on the windshield where water beads. A3: Replace wiper blades with genuine wiper blades. Important: Only exchange wiper blades if windshield no longer has water-repellent areas Note: Replacement of wiper blades is not covered under warranty and can be replaced at the expense of the customer. Remedy B: B1: Clean windshield with intensive cleaner A 000 986 40 71. Important: Do not clean the wiper blades otherwise the graphite coating will be damaged. B2: Replace wiper blades with genuine wiper blades • Note: Replacement of wiper blades is not covered under warranty and can be replaced at the expense of the customer. B3: Check the wiper arm for excessive resistance in the bearing. Restore mobility or replace wiper arm if necessary. Remedy C: Problem inherent in design for which there is no technical remedy. Exception: X204 up to 02/2014. In these vehicles, it is possible to install the design configuration of vehicles as of 02/2014. This includes wiper arms (styled arms) with improved behavior in this respect. It is also necessary to replace the wiper blades because the styled arms feature a Top Lock connection (previously Side Lock).