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post #1 of 78 (permalink) Old 07-21-2009, 08:25 PM Thread Starter
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Gas smell

Last week I had a problem with my 2003 E500, there was a strong gas smell and it will took a few seconds for the car to start. The problem was a gas leak on the sending unit. The sending unit is located under the back seat on the driver side. After lifting the seat, removing the carpet and unscrewing the cover for the sending unit; I found a gas puddle. The leak was coming from a plastic elbow right at the top of the sending unit where it connects to a hose. I called the dealer and they wanted $1,400 to fix the problem. So, I used plastic welding epoxy to temporarily fix the leak. It’s been a few days and its still holding. I found the sending unit at parts.com for $187.45; has anyone seen this for less anywhere else?

I tried to remove the sending unit but there are a few wires and hoses attached to it. Can this be removed from the top? Or do I really need to drop the gas tank like the dealership said?

How can I drop the gas tank?

Thanks
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post #2 of 78 (permalink) Old 07-21-2009, 08:56 PM
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Never work on fuel pump on W211, but this pump looks pretty close to one from W163 that I had to take off.
The hoses attached to the bottom are very likely venturi hoses, that suck the fuel from the lowest point of the tank, while the pump is located slightly higher. The pump has to come off somehow. Just make the right turn to get it off.
Epoxy don't hold on those plastics very well, so you already stretched your luck.
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post #3 of 78 (permalink) Old 07-22-2009, 09:47 AM
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bitch to your dealer and if so to your local MB rep

MB doesnt want to hear their cars having fuel spills especially close to the passenger compartment, they may cover the bill

doesnt hurt to complain nicely over the phone for 20 min to your local rep, ive heard it works on big stuff like this...
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post #4 of 78 (permalink) Old 07-22-2009, 12:32 PM Thread Starter
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I’ll try calling the dealer. It is kind of dangerous having a puddle of gas next to some electrical wires.
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post #5 of 78 (permalink) Old 07-22-2009, 12:51 PM
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remember if it fails to work it out with dealer, regional reps can pull rank and get this fire hazard fixed, make it sound bad(which it is) and it will possibly help you get it done on their tab
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post #6 of 78 (permalink) Old 07-22-2009, 01:33 PM
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Originally Posted by Raybenze500 View Post
I tried to remove the sending unit but there are a few wires and hoses attached to it. Can this be removed from the top? Or do I really need to drop the gas tank like the dealership said?
No need to drop the tank, PM your email address and I will forward the WIS for DIY replacement.
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post #7 of 78 (permalink) Old 07-23-2009, 03:06 PM
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I have the same problem! Dealer tells me that this was a problem with the 2003-2004 E Class w211. When I fill the car all the way up.The gas smell will last for days.
$1,475 fix! No way, Time to trade- in

2007 ML350, Iridium Silver/ Ash MB Tex
1996 S320LWB, Brilliant Silver Metallic / Gray Leather (SOLD)
2004 S500, Black / Charcoal Leather (SOLD)
2006 C230 Sport, Granite Grey / Black MB-Tex / Leather (SOLD)
2003 E320, Brilliant Silver Metallic / Charcoal Leather (SOLD)
2002 ML320, Everest Green Metallic / Java Leather (SOLD)

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post #8 of 78 (permalink) Old 08-01-2009, 11:23 AM Thread Starter
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Here’s an update on my car.
Kajtek1 was right, the epoxy glue only lasted a week, after that the sending unit started leaking gas again. I didn’t get far with the dealership and decided to do this myself.

To remove the sending unit, both covers under the rear seat need to be removed. Under the left side is the sending unit and under the right side is the pump. The sending unit has 3 hoses and a wire harness that will need to be unplugged from the pump; and then you can pull the whole thing out, see the pic below. Press coupling (arrows) and remove fuel
Line. At this time also remove the pump; just pull it out of the gas tank. The new sending unit, part#2114704094 ($180) already comes with new hoses and the wire harness, but the hoses are bigger and won’t fit in the bracket attached to the pump. Remove the bracket shown on the pic below and install a new bracket, part #2114710241 ($12). After installing the new bracket, the pump can be placed back in the gas tank (right side), then place the new sending unit back in the gas tank (left side), and attach the 3 hoses and wire harness back to the pump. I have a 2003 E500, the new sending unit uses a different harness from then the one originally installed in the car; therefore, I had to buy a wire harness conversion, part# 2114400507 ($15) to be able to plug in the new sending unit. Place the pump and sending unit cover back on and your finished.

Jfamondone, if gas leaks after you fill the tank all the way up, check under the back seat to see if you can see the same puddle I had. If that is the case, could it be that seal #15 is damaged?
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post #9 of 78 (permalink) Old 10-19-2009, 03:55 PM
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I just had the same problem with my 03 E500, gas smell, took it to the dealer and they wanted $775.00 and told me the reason for the high labor time was that they had to drop the tank. I Informed them I had purchased an extended warranty, and that it should be covered, while they were verifying this I found this thread, and gained a wealth of info as to the task. When the dealer called me back to tell me that it WAS a covered repair, I then hit him with both barrels from my now info. loaded gun. I told him this is the reason people can't trust dealers, they will lie to make a few extra bucks! silence, then... your car will be ready about 5:00 pm.
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post #10 of 78 (permalink) Old 01-07-2010, 08:47 AM
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Did you use the special tool

I seem to have the same problem of a leak around the filter/sending unit. Ready to do this; I want to try replacing the seal first and then the whole sending unit; did you guys have to use the special tool - claw wrench to remove the retainer over the fuel filter or is there a workaround?

Thanks

W211: 2004 E320 4MATIC
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