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Most drivers fill up their tanks around 45 to 55 times a year. During that time, it’s likely that overfilling the gas tank has crossed the mind—whether it was done on purpose or by accident. But what’s the deal with that? Is it a big deal, or just a minor slip-up?
What’s the Risk of Overfilling?

When it comes to flammable liquids, safety is key. Overfilling a gas tank isn’t just a messy inconvenience; it can actually mess up the vehicle. Most American cars have a sealed fuel system designed to handle gas fumes. Overfilling can overload this system, leading to blockages and potential damage.
How Much Damage Can It Really Cause?
So, does overfilling once or twice spell disaster? Not really. But consistently topping off the tank? That’s where problems can start to pile up. Let’s break down how folks end up overfilling and the potential fallout.
How Does Overfilling Happen?

Gas pumps have built-in safeguards to prevent overfilling. They automatically shut off when the tank is full. But sometimes, the nozzle can get squeezed again, leading to accidental spills. Some drivers even try to “top off” their tanks, hoping to squeeze in a bit more fuel for those extra miles. But that extra gas can crowd out the air needed for the fuel system to work properly, causing clogs and damage.
What Happens If the Tank Overfills?

Overfilling can lead to gasoline spilling out, which is obviously a fire risk. While small spills evaporate quickly, the real trouble comes from the damage that can happen over time. A clogged fuel system can wear out the fuel pump, leading to costly repairs down the line.
What to Do If Overfilled

If it happens, turn off the car and give it a moment. Let any excess fuel settle back into the tank and allow spilled gas to evaporate. Never pump gas with the engine running, even if the chances of a fire are low. Gas evaporates quickly, but as long as there’s a smell, there’s a risk.
Signs of Overfilling

Wondering if the tank’s been overfilled? Listen for that click when the pump shuts off. If the nozzle is squeezed again, fuel might splash back. And the fuel gauge will be maxed out.
The Dangers of Overfilling

Overfilling isn’t just about spills; it can damage key components like the engine and emissions control system. The charcoal canister can also take a hit. Regularly topping off the tank can lead to serious issues down the road.