Faulty Fuel Sensor - 23 SX XPro

[sinerge]

So I started the car a few mornings ago and the fuel gauge showed zero miles and low fuel, which was weird since just the last night there were around 80 miles of range left. I filled it up with about 1.7 gallons from a gas can and the next day I started the car I got 107 miles of range. So basically the missing miles came back. Just putting this out there in case anyone else has this issue.

 

[mentiote]

I'm having the same issue with my 2023 SX-P. It has happened twice, each time after the car abruptly cut off without fully starting. Initially fuel gauge showed empty, but 300+ miles in tank remaining. Then miles remaining when to --. The fuel gauge and miles remaining slowly crept up over a few days.

 

[sinerge]

Thanks for letting me know. I have a service scheduled for next week and will let them know it's not just me. I also noticed the range estimate is not accurate. The estimate was that I had 15 miles left, so I figured I would fuel up after work, which is about 12 miles away, but driving there it went to --- but I was still able to drive a few more miles. Anyway, when I topped up I only added 17.8 gallons, and the capacity is supposed to be 18.8. So there was over a gallon left when the estimate went to zero.

 

[2020Telly]

Two thoughts, one easy the other not as much. 1. Make sure the fuel cap is secured and locked but not over tightened. I have experienced weird issues on other vehicles when the gap cap is not secured properly and venting is not happening properly. 2. I wonder if your fuel vapor evacuation system is not purging the vapor from the take properly or the carbon activated canister is not flushing the moisture. This can lead to inaccurate fuel estimate readings by the computer. It is supposed to work after the car has been sitting a little motor sound kicks on and is hardly noticeable. I’ve heard my Telluride do it after sitting in the garage for a few minutes. There is a way to force the evacuation and force the computer to reset but I would not recommend it all the time and it won’t help if you have a leak in a vacuum seal. Basically you overfill a few times past the clicks on a full tank and it should leave less room for the vapor forcing the system to work. But be careful as overfilling past the click too much could crack the canister.

Good luck!

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[mentiote]

Sharing some pictures in case it is helpful. Issue also occurs with nearly full tank in my case. Car was refueled on a Monday. Next day Tuesday fuel gauge was "empty" but miles remaining was 341. (subsequently went to ---)

Wednesday mid-day fuel gauge up to 5/8 157mi remaining.

Wednesday afternoon, drove 16 miles, but fuel gauge went up further to 7/8 and 239 mi remaining.



This was second time it happened to me, so I took pictures. Would appreciate an update on how dealer addresses.

(Sorry can't seem to rotate these pictures)

 

[sinerge]

Sharing some pictures in case it is helpful. Issue also occurs with nearly full tank in my case. Car was refueled on a Monday. Next day Tuesday fuel gauge was "empty" but miles remaining was 341. (subsequently went to ---) View attachment 29978

Wednesday mid-day fuel gauge up to 5/8 157mi remaining.View attachment 29979

Wednesday afternoon, drove 16 miles, but fuel gauge went up further to 7/8 and 239 mi remaining.
View attachment 29980


This was second time it happened to me, so I took pictures. Would appreciate an update on how dealer addresses.

(Sorry can't seem to rotate these pictures)

So I went to get my car serviced at the dealer today and they said if they could not duplicate the issue then they will charge me $200, since Kia won't cover it! I basically told them to f off, since this car is less than 3 months old and it's not likely they can duplicate this if it's a software issue. Anyway, I spoke to consumer affairs to let them know of the issue. I would suggest you do the same, so they know people are having the issue and get a fix in.

 

[clow]

So I went to get my car serviced at the dealer today and they said if they could not duplicate the issue then they will charge me $200, since Kia won't cover it! I basically told them to f off, since this car is less than 3 months old and it's not likely they can duplicate this if it's a software issue. Anyway, I spoke to consumer affairs to let them know of the issue. I would suggest you do the same, so they know people are having the issue and get a fix in.

Honestly I doubt it's a software issue since many others would be having this issue. I would recommend discussing with the Service Manager and showing the pictures (as I suspect you did). Since it's intermittent - they won't be able to duplicate it. However, it should be enough evidence that they should replace the fuel sensor. If Kia requires them to have error codes with the fuel sensor - then they should run that diagnostic and they should find error codes.

 

[Tellthemride]

Perhaps, could be the same issue with the fuel gauge or fuel sender that has plagued some other previous model year owners in the past.

Gas Gauge

I filled the car with gas today but gas gauge is at ~ 5/8 full. I will be taking it in shortly for service (5000 miles) but in the mean time does anybody else have this issue. I apologize up front if this has been discussed before.

tellurideforum.org

Gas tank size?

Internet says 18.8 gallons. Today I was on empty (fuel range 5 miles)and was only able to put 13 gallons of gas in my tank. That seems like a small tank for an SUV. My previous Chevy Avalanche had a 30-gallon tank. I looked in the manual and can't find where it lists the size. Does anyone have...

tellurideforum.org

If Kia refuses to inspect the fuel sender unit, maybe have an independent mechanic with experience take a look.

Symptoms of a Bad or Failing Fuel Gauge Sender | YourMechanic Advice

If your fuel gauge behaves erratically or is stuck on full or empty, you may need to replace the fuel gauge sender.

www.yourmechanic.com

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[Krause]

I'm having a similar issue. Friday the car wouldn’t start, but there was clicking from the engine and every light on the dash was flashing. I charged the battery and the car started. Saturday morning the car was completely dead, so I charged the battery again to start the car, but the fuel gauge said empty despite having almost a full tank. I went to the gas station to top off the tank and the fuel gauge reset. I then went to Advanced Auto to have them check the alternator and battery; both checks said everything is good. Sunday morning the car started with no problem, but the fuel gage says the tank is empty again. Hoping to get it into the dealer’s service center tomorrow.

 

[sinerge]

It happened again! The fuel gauge said I had about 54 miles this morning, then after driving about 5 miles I looked down and notice it showed zero. As you can see in the pictures, since the last full refuel it said I had only gone 276 miles, so I knew there should be plenty of fuel left and drove another 17 miles before filling up. However, it only fueled to just over 16 gallons. So that’s over 2.5 gallons less than the stated capacity of 18.8 gallons. Considering I drove 17 miles after it said zero, I actually had about 3 gallons left. Guess I'll waste more time and bring it in again. My first Kia. Is this brand really that crappy and tries to ignore issues?

 

[sinerge]

Also, would you all consider this a safety issue? I'm about to report this to the NHTSA to investigate and force Kia to do something.

Resources Related to Investigations and Recalls | NHTSA

www.nhtsa.gov

 

[Wolf in X-Line Clothes]

On every vehicle I have ever owned with fuel range capability (which is a bunch) they always tell you that they are at zero range when you have about 2.5 gallons left in the tank. I would guess that is a safety feature in itself. I always know that on my Durango that when it says zero range that I still can go about 35miles or more. Another reason that it is a good idea to not run your fuel level too low, is that the fuel pump is usually inside the tank and the fuel keeps it cool. Running it low on fuel causes the fuel pump to run hot and will shorten its life.

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[G-752369]

I'm having the same issue with my 2023 SX-P. It has happened twice, each time after the car abruptly cut off without fully starting. Initially fuel gauge showed empty, but 300+ miles in tank remaining. Then miles remaining when to --. The fuel gauge and miles remaining slowly crept up over a few days.

Just happened to me with 2022 telluride. Dealership claims everything is working properly and I told them clearly not if it took 3 days for my full tank of gas to register as full with the analog and digital dashboard guages.

 

[Seabeee]

I purchased a 2023 Telluride SX X-Pro on 4/8/23. Dealer filled up tank on delivery, but a day later and after driving approximately 60 miles I received an out of fuel message and gauge showed empty. I topped off tank and gauge still indicated empty, but began creeping up over the next 2 days until showing full. All good until yesterday. I had filled tank and driven 59 miles when again received a out of fuel message and gauge indicating empty. Since yesterday evening the gauge has crept up and is currently showing about half a tank, even though I'm sure I have 3/4 tank or more. I spoke to dealer and advised of the issue and the service manager said he was aware of a few other cases like this, but had yet to see in person. Didn't offer any other input. Has anyone had any success with a definitive fix or is there any traction with Kia acknowledging an issue?

 

[3rdKia]

I just experienced the same problem as Krause above (in a 2023 Telluride with 700 miles on it). First the car wouldn’t start, with a clicking sound and flashing dash. That problem was the battery. But now the fuel gauge says empty despite being topped off. Something is killing my battery and I don't know if the faulty fuel gauge is the cause or the effect.

 

[sinerge]

I brought mine in for diagnostics a couple days ago, since they agreed to waive the $250 fee if they couldn't duplicate it, which they couldn't. They've reached out to their tech line for additional support, so still pending resolution.

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[alingis]

Having the same issue on a 2023 Telluride SX Prestige X-Line. This morning is the second time it happened. The first time we got to “0”, we thought it must be us. This morning it happened after driving approx. 80 miles last night (initial estimated mileage to empty before leaving was approx. 250). When starting the vehicle this morning, est. mileage remaining is “0” again. We will begin documenting better for proof, but it is definitely difficult due to only being an intermittent issue.

 

[sagarmehta8]

I brought mine in for diagnostics a couple days ago, since they agreed to waive the $250 fee if they couldn't duplicate it, which they couldn't. They've reached out to their tech line for additional support, so still pending resolution.

Hi,
Was their tech line able to provide the root cause and fix it?

Thanks!

 

[Cskiper]

I bought a 2023 Telluride SX Prestige X-Line on May 2, 2023. Today, May 28, I just had the experience you all are describing. I had a full tank of gas a few days ago and this morning the fuel gauge showed empty. I stopped and topped off… only 6 gallons. I only have 330 miles on this car!

 

[NewKiaGuy]

Honestly I doubt it's a software issue since many others would be having this issue. I would recommend discussing with the Service Manager and showing the pictures (as I suspect you did). Since it's intermittent - they won't be able to duplicate it. However, it should be enough evidence that they should replace the fuel sensor. If Kia requires them to have error codes with the fuel sensor - then they should run that diagnostic and they should find error codes.

I would guess it is a software issue (I am a FW engineer to give a little weight). It happened to mine 1 week after purchase after a refill the day before. Unplugged battery and plugged it back in and has been working fine since.
Software is complicated...