2013 Sorento runs then won't start for several hours

Have a tale of woe for you
2013 KIA Sorento, 2.4 LX AWD, 170,000 kms on it.

Starts up, runs for about an hour, then wont restart for 2-3 hours. When restarted will stall approx every 1km. Ignition turns will gently chug a second or two so feels like it has no fuel. At one point I added 10 liters of gas when it still said 120km to empty, and it restarted straight away. I thought it may be a faulty fuel gauge, so filled the tank, but that only got me 100m lol.
Figured it all pointed to rogue sensors so replaced again, no joy.

Heres what has been done in the past year. Before you question my sanity, I only became the proud owner of this project in January, so didnt spend the $8k the poor previous owner did last year on this to get nowhere. Apart from this issue, car performs as normal.

Jan 20 - 2 x Camshaft and Crankshaft Sensors 170km
June 19 - New crankshaft sensor 163km
June 19 - Tested evap system. Leaking past pressure system, replace gas cap 162km
Jan 19 - Engine light on, vehicle continues to stall. New Manifold catalytic, converter assy 152km
Jan 19 - O2 sensor replaced 153km
Jan 19 - New fuel pump 153km
Jul 18 - Spark plugs 136km

My next thought would be checking the fuel basket for excess crap in it, and maybe flush the fuel lines? Failing that, might be the ECM maybe?
Any input (apart from an exorcism) would be greatly appreciated.

I think you are on the right track it sounds like a fuel tank internal issue, I am not familiar with the 4x4 Sorrento if it has a saddle style fuel tank as many modern 4x4 do it must have some kind of system internal to the tank to transfer fuel to the side of the tank with the fuel pump.

Although I am also wondering if it could be a fuel tank venting issue ie vacuum building up in the fuel tank.

Simple checks to point us in the right direction :

(1) Run the car until it cuts out then try giving the engine some substitute fuel by spraying carb cleaner or propane into the air intake ---- if the engine tries to run it is fuel issue. Note carb cleaner or propane not "EeezieStart" as this type of ether based product will often cause a gasoline engine to start by "dieseling".
(2) If the engine dosen't fire up it points to both fuel and spark are missing which is an electronic control issue.
(3) But iIf the engine tries to run on the substitue fuel try removing the fuel filler cap
(4) If that dosen't work check for power and control of the injectors with a tungsten bulb test lamp.
(5) If the injectors are being fired then the fuel system at the tank and pump needs investigated.

I had a quick look at the layout --- saddle tank type with an in-tank filter on the opposite side of the tank from the pump. This layout is generally similar to some MG-Rover models. If you access the fuel filter on the left side of the tank and the fuel pump on the right side of the tank and examine the filter assembly and the pump assembly and any pipe work inside the tank you will likely find your issue.
Take care with the fuel level sender as these are easily damaged on this type of system particularly if the fuel level is high.



www.kiapartsuk.com/fuel-filter-311122p00...l-engines-1332-p.asp

Andy - thanks so much for the detailed response. Will give it a whirl and let you know how I get along. Thanks again, James