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On my 2000 ML 320, I have found that I can get at least 2 more gallons in the tank after the first shut off, if I fill the remainder very slowly. I have never noticed any gasoline leaks. I like the extra range that the additional gallons give me before the next fill up. I have never noticed any adverse effects. I do make sure the cap is on tightly.
Sorry to hear about your problem, and I hope that it is a simple fix.
George
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