Gas Tank Overflow!
#1
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Thought I’d put this out there so no one else makes the same mistake I did last night: Went to fill the tank on my new ES300h, needed at least 10 gallons. I popped the (Matador Red Mica) door open about 2 miles before reaching the gas station (my stupid habit). The non English speaking attendant opened the cap and began filling the tank, walked away, and the nozzle cut off with a splash after about 2 gallons went in. He came back started it again and the tank overflowed all over the quarter panel and rear left tire. Probably a pint or two of gas. A comical exchange of words, he said tank is full, I said pump is NG. I quickly paid, high tailed it home to wash the car and tire with soap suds. The takeaway: Read your Owner’s Manual (page 174) about refueling! Never pop your tank door ahead of the gas station! The manual will tell you exactly why!
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scubapr (05-24-24)
#2
Intermediate
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Thought I’d put this out there so no one else makes the same mistake I did last night: Went to fill the tank on my new ES300h, needed at least 10 gallons. I popped the (Matador Red Mica) door open about 2 miles before reaching the gas station (my stupid habit). The non English speaking attendant opened the cap and began filling the tank, walked away, and the nozzle cut off with a splash after about 2 gallons went in. He came back started it again and the tank overflowed all over the quarter panel and rear left tire. Probably a pint or two of gas. A comical exchange of words, he said tank is full, I said pump is NG. I quickly paid, high tailed it home to wash the car and tire with soap suds. The takeaway: Read your Owner’s Manual (page 174) about refueling! Never pop your tank door ahead of the gas station! The manual will tell you exactly why!
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#3
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Overfilling can have serious consequences/damage to the EVAP system; not just the panel paint. That could cost you $$$ in repairs down the road. If possible have it check.
Last edited by scubapr; 05-24-24 at 11:58 AM. Reason: Add video
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RocketMan295 (05-24-24)
#4
Lexus Test Driver
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What does the overflow have to do with popping the tank door before you shut down? Don't make us open up the manual😉 especially since page 174 in my manual refers to driver support systems.
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bc6152 (05-24-24)
#5
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![](https://cimg9.ibsrv.net/gimg/www.clublexus.com-vbulletin/282x264/lexus_manual_p174_refuel_1_e129d1a39f7cdb2e75c46a92340df47435f36114.jpg)
![](https://cimg4.ibsrv.net/gimg/www.clublexus.com-vbulletin/278x199/lexus_manual_p174_refuel_559190d7f269bafb2bf814a8ac91358ffd8eb2d5.jpg)
Last edited by scubapr; 05-24-24 at 12:20 PM. Reason: Add anothe pic.
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#6
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That video was spot on. As well as the text of page 174 (Some day I’ll learn how to attach something, I’m tech-illiterate) Bottom line: There’s a valve somewhere in the filler neck. I can’t prove it, but somehow I think there’s more to simply popping the door than meets the eye. From now on, I’ll follow the owner’s manual instructions. Just like I tell my kids to do!
#7
Lead Lap
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I never open the fuel filler door ahead of time but I thank you for this good information as I'm sure it will help someone who did what you did. Had no idea about the interior valve timing.
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#8
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That video was spot on. As well as the text of page 174 (Some day I’ll learn how to attach something, I’m tech-illiterate) Bottom line: There’s a valve somewhere in the filler neck. I can’t prove it, but somehow I think there’s more to simply popping the door than meets the eye. From now on, I’ll follow the owner’s manual instructions. Just like I tell my kids to do!
![](https://cimg0.ibsrv.net/gimg/www.clublexus.com-vbulletin/699x996/es_300h_fuel_diagram_bbf09827bd2b8b99c410d7de76059b6655c1c58e.jpg)
#9
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That’s all because of the EVAP system. On Hybrids it is a very complicated system.
#11
Pole Position
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Interesting thread regarding the valve activated by the fuel door. Another good reason to be on CL!
I've known about the other issue, not overfilling, since 1990. I bought my dad's 1985 MR2 and wasn't happy with the small fuel tank, so I routinely topped it off. That is, until my evap system failed and indicated I needed a new charcoal canister (not cheap). I cutout my practice of topping off, and the check engine light eventually reset, and never reared its ugly head again!
I've known about the other issue, not overfilling, since 1990. I bought my dad's 1985 MR2 and wasn't happy with the small fuel tank, so I routinely topped it off. That is, until my evap system failed and indicated I needed a new charcoal canister (not cheap). I cutout my practice of topping off, and the check engine light eventually reset, and never reared its ugly head again!
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scubapr (06-03-24)
#12
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ptthere (06-05-24)
#13
Pole Position
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Generally, the design of this fuel fill valve being activated by the opening of the fuel fill door seems suspect. It's fine 99.99 % of the time, but not always as OP found out the hard way. These systems need to be 100% fool proof!
#14
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Sometimes is hard to imagine all possible scenarios by a user (no offense to OP). Perhaps the auto close is there to protect against something else worst to the engine.
Owners manual clearly specifies this, but most people rarely read them.
Still very interesting thread / issue.