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2004 Aerio - Spooky gas sensor / gas level mystery

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New User

Jul 4, 2017, 8:53 PM

Post #1 of 3 (645 views)
2004 Aerio - Spooky gas sensor / gas level mystery Sign In

I'm facing a mystery that I'm hoping you guys can help me solve.

My 2004 Suzuki Aerio (2.3L / 140,000 milometers) has had the service engine light with gas pressure / evap code for a few months now, which I haven't done anything about yet.

Every weekend I drive to my cabin and back, 220 km round trip, and then gas up afterwards, which is always about 28 or 30 liters of gas (about 8 gallons). BUT this weekend after the same trip, the tank was full after only 15 liters (the nozzle stopped filling automatically, plus the car's fuel meter level reads full).

How is this possible? Suppose the car's sensor is faulty and telling me it's full when it's not -- I'm assuming that wouldn't also cause the gas station's nozzle to stop early. Also, my car was parked under heavy rain this weekend, so maybe water somehow how into the tank -- but I assume the car wouldn't be running relatively normally if 10 to 15% of the tank was filled with water?

Any ideas?

Hammer Time
Ultimate Carjunky / Moderator
Hammer Time profile image

Jul 5, 2017, 4:23 AM

Post #2 of 3 (614 views)
Re: 2004 Aerio - Spooky gas sensor / gas level mystery Sign In

You could have venting issues preventing you from filling the tank but that wouldn't explain the gas gauge problem.
My suggestion would be to have the EVAP issues diagnosed with a smoke machine and go from there. See what that turns up.


We offer help in answering questions, clarifying things or giving advice but we are not a substitute for an on-site inspection by a professional.

Veteran / Moderator
Sidom profile image

Jul 5, 2017, 10:16 AM

Post #3 of 3 (593 views)
Re: 2004 Aerio - Spooky gas sensor / gas level mystery Sign In

As HT already said....Are you sure the gas pump didn't click off early?

There are some other factors that could effect this......I'm assuming you fill the tank before the trip and these are number from the return fill up???

I don't know the terrain you were driving or conditions but actually the last numbers sound more in range for that model ...15 liters or fuel for 220 km.. that's 35 mpg, which is what a 4 cyl Alero is rated at on the highway......Your usually numbers work out to about 18 mpg....which is below the city rating of 26 mpg......Fuel economy numbers always need to be taken with a grain of salt.....they are estimates.....But yours do seem skewed a bit......Sounds like its not in total fuel control....

For this one though.....I'm leaning more toward the tank didn't get as full as it normal did...

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