2018 RS3 Tank Filling Issues

[justaname]

Hello everyone, I am new here and new to DIY repairing my RS3. I recently bought a VCDS and I am trying to sort out my problem with filling my tank. The issue started when I was attempting to fill my tank and the pump was shutting off every couple seconds. My first instinct was to drive to another gas station and use a different pump, but as I got out on the road the car started misfiring a little. I pulled over opened the gas cap and there was a gurgling sound which I assume is air escaping the left side of the fuel tank as gas is pulled over to that side. I waited until the gurgling stopped and got back on the road and drive the 1 mile or so to the house. After this happened I ended up taking it to my local dealer to have it diagnosed, I figured it was the charcoal canister which they confirmed was bad, but the dealer also said that I needed to replace the entire fuel tank as it was "faulty". They would not give me the specifics of what was faulty with it, just that it needed to be replaced along with the charcoal canister. I ended up bringing the car home, ordering a used charcoal canister and replaced it myself a couple of hours ago. This did not solve the issue, same thing is happening and I am just hoping I didn't kill this charcoal canister in the process. I have a replacement N80 purge valve on the way, but I don't feel like that is the issue here for whatever reason. Has anyone else had a similar issue with the RS3? I cannot seem to find anyone who has had my exact symptoms. I would rather not replace the tank unless I absolutely have to. Any guidance here would be much appreciated. Thanks.

[AdamSheikh]

I just went through this (for the second time) with my MK7 GTI. While dealers are quick to recommend replacing the entire fuel tank, the actual issue is the suction pump in the tank failing. This causes fuel to back up into the charcoal canister and cause all sorts of EVAP issues etc. If you continue driving like this, fuel will likely start to leak out of the charcoal canister. Not sure if the suction pump is a serviceable item in the RS3 fuel tank like it is on GTI, but I can't imagine the fuel systems are wildly different between GTI, R, and S3/RS3. At the very least, you will need the suction pump, charcoal canister, and N80 to be changed.

Now here's the interesting part that I would recommend you do some digging on. On my VW, I had the entire tank replaced under warranty the first time back in 2015. Then there was a recall for the suction pump in 2016 (which was performed as a precaution on my car). This latest failure happened just 2 weeks ago and the dealer wanted to do the tank again (on my dime). I called VW customer care and discovered there was a factory extended warranty on the suction pump - 15 years/150k miles. I got the suction pump replaced at no charge, as well as the charcoal canister and N80 purge valve (as "consequential damage coverage"). I'd recommend you call Audi support and see if anything similar exists on your car, or if they can at least offer some "goodwill" assistance.

[AdamSheikh]

Here is a YouTube video explaining the issue - looks like a Golf R tank, so likely the same as yours.
https://www.youtube.com/watch?v=AgM1_ZzYoFo

[justaname]

I just went through this (for the second time) with my MK7 GTI. While dealers are quick to recommend replacing the entire fuel tank, the actual issue is the suction pump in the tank failing. This causes fuel to back up into the charcoal canister and cause all sorts of EVAP issues etc. If you continue driving like this, fuel will likely start to leak out of the charcoal canister. Not sure if the suction pump is a serviceable item in the RS3 fuel tank like it is on GTI, but I can't imagine the fuel systems are wildly different between GTI, R, and S3/RS3. At the very least, you will need the suction pump, charcoal canister, and N80 to be changed.

Now here's the interesting part that I would recommend you do some digging on. On my VW, I had the entire tank replaced under warranty the first time back in 2015. Then there was a recall for the suction pump in 2016 (which was performed as a precaution on my car). This latest failure happened just 2 weeks ago and the dealer wanted to do the tank again (on my dime). I called VW customer care and discovered there was a factory extended warranty on the suction pump - 15 years/150k miles. I got the suction pump replaced at no charge, as well as the charcoal canister and N80 purge valve (as "consequential damage coverage"). I'd recommend you call Audi support and see if anything similar exists on your car, or if they can at least offer some "goodwill" assistance.

Thanks for the information, it really helped clear some things up for me. I did see the recall for the VWs suction pump. I will definitely be calling Audi support and seeing what they can do for me. They did tell me it would take a month to get the new tank in, if they ended up replacing it haha. Thanks again, much appreciated!

[justaname]

Here is a YouTube video explaining the issue - looks like a Golf R tank, so likely the same as yours.
https://www.youtube.com/watch?v=AgM1_ZzYoFo

Super helpful video too. Thank you sir!

[pandafam]

hey what ended being your fix? im currently facing the same issue on my 2018 RS3 as well.

[mlharmon]

Same issue here. I'm really concerned about the insanely-strong gas fumes that seem to seep through the garage walls after I fill up my 2018 RS3. I'm worried about the gas hot water heater being just feet away in the garage, but the dealership wants around $5,800 to resolve this issue and I just can't do it. :(

[s3ck]

I'm currently going through this now with my 8v RS3 being at the dealer for about 8 months. It was difficult to diagnose the problem initially and Audi didn't have a fix. It started with a check engine light and drive train malfunction warning. It seems like we are near the end now and not sure if everything I experienced relates to the gas tank issue, but the codes stated that one of the banks running rich at idle. It turned out there was a software update from Audi around Nov '23 to address the issue. The dealer started with the update, then had to replace the spark plugs, then the high-pressure fuel pump, in that order for the code to go away. Then with the new fuel pump they noticed that there was a lot of suction when trying to remove the fuel take cap. That lead them to check the fuel sensor in the tank which turned out to be faulty. So.. they are replacing the tank now.

[Skunkwerx]

I'm currently going through this now with my 8v RS3 being at the dealer for about 8 months. It was difficult to diagnose the problem initially and Audi didn't have a fix. It started with a check engine light and drive train malfunction warning. It seems like we are near the end now and not sure if everything I experienced relates to the gas tank issue, but the codes stated that one of the banks running rich at idle. It turned out there was a software update from Audi around Nov '23 to address the issue. The dealer started with the update, then had to replace the spark plugs, then the high-pressure fuel pump, in that order for the code to go away. Then with the new fuel pump they noticed that there was a lot of suction when trying to remove the fuel take cap. That lead them to check the fuel sensor in the tank which turned out to be faulty. So.. they are replacing the tank now.

Under any applicable warranty or recall? If not... can you share the ballpark cost to replace the tank?

[pandafam]

My issue has started around 8 months ago. And now it’s gotten to the point with everytime I come home I can smell it within the garage walls. Please respond with how much your dealer charged you.

[Makersmark]

I had mine replaced at an indy shop. $2600 parts and labor.

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[nesbit]

Am I wrong to think that $6000 for this, $1500 for a water pump, etc, are unreasonable costs given how common these problems are? I don't like the thought of those kinds of potential bills looming overhead. I don't recall replacing a fuel tank to be a common thing on other cars this young. Am I whiney or is this unreasonable? Anyone get an extended warranty like car shield? If so how much are you paying?

[pandafam]

No literally. I’ve honestly just garaged the car and hardly take it out now. When I do, it takes me forever just to fill the car up. Gas cuts off every few seconds. It takes like 5-6 minutes to fill the car up to near full. I have an extended warranty from Endurance. I didn’t know anything about them and got sold by the dealer for it. I have been reading terrible Reddit reviews now of them, so that’s great. But I am finally starting to gain interest in my car again so I’m finally just gonna see what happens with the warranty this week. Don’t have high hopes of them honoring it but we shall see. This constant issue and my maps randomly corrupting was the last straw. It just turned me off from the car and it has since turned into a garage queen. I love it but these issues are just so irritating and so stressful.

When it’s completely functional, maintenance up to date, perfect etc. I am still stressed and I feel like I can’t fully enjoy my own car bc I feel like something else random will break 😂. I don’t really have high miles either, I’ve recently hit 40K & I’ve had the car since 16K.