Have you tried multiple pumps/stations? The angle of the nozzle makes a difference. There's one particular gas station I frequent where I have to readjust the nozzle, but all others are just fine.

 

Just push it in more.

Make sure it's locked in.

 

In my car I have to go no further than the first click on the handle. Anymore than that and it clicks off.

 

Depending on the station, their fuel, additives, pumps, flow rates, pump handle design, etc., fuel will foam more or less when pumping. The more foam, the harder it is to fill in one shot. It may not be anything wrong with your car.

 

I thought this problem was caused by a faulty or worn out charcoal filter assembly? fig. #2:

http://www.realoem.com/bmw/enUS/showparts?id=BD53-USA-09-2004-E46-BMW-330Ci&diagId=16_0420

 

Problem could be the fuel pump nozzle, if you have had similar problems with multiple fuel pumps or stations, the problem could be a restricted charcoal canister as someone mentioned.

Could also be a pinched, kinked or clogged vent tube/hose that leads back up toward the fuel fill pipe.

 

There is one station that I've been to where this happens and every other station I've been to has been no problem, so I think maybe just that particular nozzle shape caused problems. Point being, go to a few different stations and make sure this doesn't happen everywhere.

 

Issue with EVAP system. Most likely is bad charcoal canister and/or blocked lines.

 

Definitely have tried multiple gas stations, angles, and nozzle distance in the tank. Also tried lowest option with gas. The car has done this for the last year. Just getting tired of it.

Never thought about the charcoal canister.. I'm seeing an option to delete it?

Sent from my VS995 using E46Fanatics mobile app

 

Do not delete the charcoal canister.

New ones can be expensive as I recall, might see if you can find a used one if it is not to difficult to replace.

 

Looks like Mango did this as well..

http://forum.e46fanatics.com/showthread.php?t=948243

Sent from my VS995 using E46Fanatics mobile app

 

No, no, no, and no. Mango was talking about a vacuum canister that stores vacuum for the exhaust flap actuator. The charcoal canister takes gasoline vapours, stores it, then the ECU commands the EVAP purge valve open to pump fuel vapours into the intake. Do not mix these two canisters up.

 

OP, I'm sorry to say your car is most likely totalled.

 

New the canister is close to $300! Kind of stupid expensive. Might check hoses for kinks or damage and look for a used canister.

While I am not a bit proponent of a used canister, they rarely have problems and due the high cost, I would try a used canister first.

I know people have tested or compared canisters with smoke testing to see if one is restricted more than the other. There is not a real test that I know of, but at the end of the day, this may be a useful way to compare 2 canisters.

Also not 100% familiar with all the parts that make up the Evap system as they are fairly problem free. You might see if you car also has the 3/2 changeover valve as well and make sure there are not other small parts or valves that may impact the proper venting of the tank while filling.

 

Few years and I wanted to update my fix... i removed the hoses to make sure there were no clogs. One hose going into the canister had a TON of the little charcoal pebbles that looked like it was blocking the airway. (Maybe it is supposed to be that way)?

Anyways.. I went ahead and let them fall into a cup and made an airway going into the canister. So far I have had no issues.

GL to anyone else maybe searching around finds this thread.

 

If there were charcoal pellets in a hose, then this means the charcoal canister has failed and this charcoal can possibly work its way up to the Evap purge valve and even be sucked into the engine.

Time to find a good used canister and replace it.

 

I could not find any local canisters at the yards and the ones online are around $300 so I ended up making a homemade filter and my issue is now solved!

Sent from my [device_name] using E46Fanatics mobile app