WHEN 2005 E320 HAS GAS TANK FILLED, THERE IS AN OVERWHELMING FUEL ODOR IN THE PASSENGER COMPARTMENT AND OUTSIDE THE VEHICLE. THE FUMES DISSIPATE WHEN THE FUEL LEVEL DECREASES FROM FULL TO 3/4. CAR WAS TAKEN TO MERCEDES DEALER FOR SERVICE AND THIS PROBLEM WAS LISTED FOR THE REPAIR PERSON. THEY FOUND NO PROBLEM. YEAR AND A HALF LATER, I AGAIN ASKED MERCEDES DEALER TO LOOK AT THIS ISSUE. THEY SAID IT WAS A LEAK IN THE FUEL SENDING UNIT WHICH IS CONNECTED INTO THE TOP OF THE GAS TANK. AT A COST OF $800, THE FUEL SENDING UNIT WAS REPLACED. I PICKED UP THE VEHICLE AND THE FUEL SMELL INSIDE THE CAR WAS SO STRONG IT MADE ME AND TWO CLIENTS NAUSEOUS WITH SEVERE HEADACHES THE FOLLOWING DAY. I RETURNED THE CAR TO THE DEALER, AND UPON FURTHER INSPECTION, THEY NOW TELL ME THE FUEL SENDING UNIT WAS LEAKING BUT THE GAS TANK ITSELF ALSO IS CRACKED AND LEAKING WHICH NEEDS TO BE REPLACED FOR ANOTHER $2,000. I OPENED A COMPLAINT WITH MERCEDES BENZ USA. AFTER THEIR SHAM OF AN INVESTIGATION, THEY SAID THEY WOULD OFFER ME A 50% DISCOUNT ON THE FUEL TANK REPLACEMENT OR ASSISTANCE ON THE PURCHASE OF A NEW VEHICLE. THE CAR NOW HAS 118,000 MILES AND IS OUT OF WARRANTY. I HAVE NO CHOICE BUT TO MAKE THE REPAIRS. YOU SHOULD NOT HAVE TO REPLACE A GAS TANK ON A VEHICLE OF ANY AGE, AND I AM AFRAID OF CONTINUED SAFETY PROBLEMS FROM POOR ENGINEERING DESIGN WITH THE REPLACEMENT PARTS IF THE CAR IS INVOLVED IN ANY ACCIDENT. *TR