2004 Dodge Grand Caravan Fuel System Problems

Your fuel pump has developed hairline cracks where it connects to the fuel line, causing a strong fuel smell and fuel vapors around the vehicle. This creates a potential fire hazard since the leaking fuel is located near your hot muffler. The fuel pump will need to be replaced to fix this problem.

Your van stalls within a few miles after you fill up the gas tank, which has happened to you on the highway at 55 mph and forced you to pull over quickly. Dodge extended the warranty on fuel tanks for vans built after September 2003, but your August 2003 van falls outside that coverage window. The fix will likely involve inspecting or replacing the fuel tank and related fuel system components.

Your vehicle has stalled unexpectedly while driving multiple times — once in a busy intersection and once on the highway at 60+ mph, forcing you to coast with no power steering. Additionally, your car stalls almost every time you fill up the gas tank and leave the station, though it restarts after about a minute. This pattern suggests a fuel system issue that may need diagnostic testing and potentially fuel pump or fuel pressure regulator replacement.

Every time you fill up the fuel tank, your Caravan stalls and runs very roughly afterward. You've noted that a recall was issued for Caravans built starting September 1, 2003, but your vehicle was built on September 29, 2013, which may fall outside the original recall window.

After you fill up your gas tank, your van stalls without warning and is hard to restart. The problem happened multiple times, though the vehicle eventually did start again each time. The issue wasn't diagnosed or fixed. The fix will likely involve inspecting the fuel system components, including the fuel pump, fuel injectors, and fuel pressure regulator.

Your engine stalls out about 10-15 seconds after you fill up the gas tank, typically when you're turning onto the highway. This has been happening intermittently for a couple of years. The issue likely involves the fuel system's ability to properly regulate pressure or vent when the tank is full.

Your car stalls out shortly after you fill up the gas tank at a gas station. The issue is reportedly caused by a faulty check valve in the fuel system, and the repair requires replacing the entire fuel tank.

After filling up your gas tank, the check engine light comes on and indicates an emissions leak. This causes fuel vapors to build up inside your van after each refueling. If you fill the tank completely, your engine may stutter and sometimes stall shortly after fueling. The issue likely involves a faulty gas cap, fuel vapor canister, or related emissions system component that needs inspection and replacement.

Your van stalls immediately after refueling at gas stations, creating a dangerous situation on busy roads. This happens consistently when you fill up, though the van restarts and runs normally afterward. The issue appears to be related to the fuel tank or fuel sensor and may require diagnostic testing and potential replacement of fuel system components.

Your van stalls shortly after you fill up the gas tank at the station. While it usually restarts after pumping the gas pedal repeatedly, this is dangerous when it happens in traffic. You've already had the fuel pump and filter replaced without solving the issue, and the problem appears to be caused by a faulty valve on top of the fuel tank that requires replacing the entire tank. The repair will likely involve draining and removing the fuel tank to access or replace the tank vent valve.

Your car shuts off and stops running shortly after you fill up the gas tank, and this has happened multiple times while you're driving in traffic. This is a dangerous situation since the engine suddenly dies while you're on the road. The issue likely involves the fuel system's ability to properly handle a full tank, and may require inspection of the fuel vapor canister or related fuel pressure components.

Your van shuts off immediately after you fill up the gas tank, and this problem has been happening for over 2 years. The issue is a faulty vapor separator valve on top of the fuel tank that Dodge no longer sells as a separate part. The only repair option available is to replace the entire fuel tank, which costs around $1,600.

Every time you fill up your gas tank, the engine runs roughly, hesitates, or stalls when you pull out of the gas station—even if you only added 5 gallons to a half-full tank. This has happened in the middle of intersections while turning, creating a safety risk. The issue appears to be related to a valve above the tank that cannot be replaced separately, requiring replacement of the entire fuel tank.

Your fuel pump has developed hairline cracks in multiple locations and is leaking gasoline. The damage appears to have been there for a while before you noticed it. This seems to be a recurring problem affecting multiple 2004 Dodge Grand Caravan models. Fixing this will likely require replacing the fuel pump assembly.

TL* THE CONTACT OWNS A 2004 DODGE GRAND CARAVAN. THE CONTACT STATED THAT THE VEHICLE WOULD STALL IMMEDIATELY AFTER REFUELING. THE CONTACT INDICATED THAT THE FAILURE HAD OCCURRED ON MULTIPLE OCCASIONS AND IN SOME INSTANCES THE VEHICLE WOULD STALL UP TO TWO TIMES BEFORE OPERATING AS NORMAL. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE BUT NO SOLUTION WAS OFFERED. THE FAILURE MILEAGE WAS 115,000.

NOTICED FUEL SMELL AND VEHICLE STALLING OR HESITATING AFTER FUELING, FOUND FUEL LEAK COMING FROM VERY SMALL CRACKS ON FUEL PUMP HOUSING TOP LOCATED ON THE PASSENGER SIDE OF THE VAN CLOSE TO THE EXHAUST SYSTEM. *TR

BEGINNING AROUND AUGUST 2012, MY 2004 DODGE GRAND CARAVAN ANNIVERSARY EDITION BEGAN TO SPUTTER AND STALL IF I EVER FILLED THE GAS TANK COMPLETELY. IF I DID NOT CONTINUE TO FEED GAS TO THE ENGINE, THE ENGINE WOULD STALL. AT STOPLIGHTS I WOULD NEED TO PUT THE CAR IN PARK AND REV THE GAS AND THEN SIT IN PARK UNTIL I WAS ABLE TO MOVE. THIS WOULD CONTINUE FOR APPROX 2-3 MILES. IN SUMMER 2013 IT BEGAN HAPPENING EVEN IF THE CAR WAS NOT FILLED TO CAPACITY. REPAIR SHOPS TELL ME IT'S THE TYPE OF GAS OR THERE IS WATER IN THE GAS LINE, BUT MY RESEARCH TELLS ME THIS IS A KNOWN CARAVAN ISSUE. MY REQUESTS FOR REPAIR INVESTIGATIONS ARE NOT TAKEN SERIOUSLY. SO MY SOLUTION IS TO NEVER FILL THE CAR BEYOND 3/4 TANK - SUPER INCONVENIENT. AS A RESULT, THE SPUTTERING DOES NOT HAPPEN AS MUCH ANY MORE, BUT THE SITUATION IS DANGEROUS AND SCARY. I AM JUST WAITING FOR THE ENGINE TO FAIL IN THE MIDDLE OF A BUSY ROAD SIMPLY BECAUSE I'VE GOTTEN FUEL. *TR

MY VAN LEFT SMALL FUEL MARKS IN DRIVEWAY, I INVESTIGATED IT PHYSICALLY AND FOUND FUEL TO BE LEAKING BY FUEL PUMP HOUSING NEAR A FUEL LINE, I ASSUMED IT WAS LEAKING FROM THE O-RINGS ON QUICK DISCONNECT LINE. I REPLACED O-RINGS AND THE PROBLEM STILL EXISTS. I GOOGLED THE ISSUE AND TO MY SURPRISE THERE ARE MANY SIMILAR ISSUES, PEOPLE EXPLAINING HOW THEIR VEHICLES WHERE LEAKING IN THE SAME LOCATION. AFTER BROWSING I FOUND A WEBSITE WHERE THERE WAS A PICTURE SHOWING FRACTURES ON THE HOUSING NEAR THE FUEL LINE THAT I HAD WORKED ON. SURE ENOUGH I RECHECKED MY VEHICLE AND THERE WERE THE FRACTURES. LEAKING FUEL. I JUST WANTED TO POST THIS ON THIS WEBSITE TO INFORM OTHER OWNERS, THAT IF THEY SMELL FUEL FROM THEIR VAN, THEY SHOULD GET THIS ISSUE CHECKED ASAP. THIS IS A REAL HAZARD, AND COULD BE REALLY DANGEROUS. *TR

THIS INCIDENT OCCURS EVERY TIME I FILL UP WITH FUEL. IT BEGAN AT APPROXIMATELY 35,000 MILES AND CONTINUES UNTIL THIS DAY AT ABOUT 116,000 MILES. INCIDENT DESCRIPTION: I ENTER THE GAS STATION. I FILL UP WITH FUEL UNTIL THE PUMP STOPS, NOT A "TOP-OFF". I START THE IGNITION AND BEGIN TO DRIVE AWAY. THE ENGINE STUTTERS AND SOMETIMES STALLS COMPLETELY. AFTER A SHORT DISTANCE, 3 MILES OR SO, IT RUNS NORMALLY. RECENTLY AFTER MY KNEE SURGERY, MY WIFE WAS DRIVING AND PULLED OUT INTO TRAFFIC, LEFT HAND TURN, AFTER A REFUEL. WE WERE TRYING HIGH-TEST ETHANOL FREE GASOLINE. WELL SHE MADE IT INTO THE CENTER TURNING LANE AND WAITED HER TURN. WHEN AN OPENING ARRIVED SHE PRESSED THE ACCELERATOR AND THE VAN STARTED AND FAILED COMPLETELY, LEAVING US HALF-WAY IN THE LANE FOR ONCOMING TRAFFIC. THANKFULLY THE ONCOMING TRAFFIC SLOWED AS THEY BLEW THEIR HORNS AND SHE WAS ABLE TO RESTART THE VAN AND BEGIN TO DRIVE. THIS WAS A MOST MISERABLE EXPERIENCE ESPECIALLY SINCE WE HAD ALL THREE OF OUR SMALL CHILDREN IN THE VAN WITH US. SOMETHING REALLY NEEDS TO BE DONE TO CORRECT THIS ONGOING AND DANGEROUS ISSUE. *TR

THE 3.8L ENGINE STALLS AFTER ALMOST EVERY FUEL FILL-UP AND BEGAN IN EARLY 2010. WITHIN 1-2 MILES AFTER A FUEL UP, THE VEHICLE WILL BUCK AND SPUTTER AND OFTEN TURN OFF COMPLETELY. IT GETS BETTER AFTER 3-5 MILES. IT APPARENTLY IS A KNOWN ISSUE WITH MANY DODGE OWNERS, NOT JUST MINIVANS. I HAD TWO 2006 DODGE CHARGERS (R/T AND SRT8) THAT BOTH DID THE SAME THING. I NO LONGER OWN THE CHARGERS BUT STILL HAVE THE 2004 CARAVAN. THIS A DANGEROUS AND UNPREDICTABLE ISSUE THAT HAS SOMETHING TO DO WITH THE TANK MOUNTED VAPOR SEPARATION VALVE AND THE VAPOR RETURN SYSTEM. THE VEHICLE IS NOT "TOPPED OFF" WHEN FUELING WHICH HAS BEEN KNOWN TO CREATE THE ISSUE. THANKS. *TR

ENGINE STALLS WITHIN A MILE OR SO AFTER FILLING FUEL TANK. ISSUE BEGAN AT 31,000 MILES AND VEHICLE CURRENTLY HAS 35,280 MILES. HAS OCCURRED EVERY TIME FUEL TANK IS FILLED SINCE THE FIRST INCIDENT AT 31,000 MILES. *TR

TL* THE CONTACT OWNS A 2004 DODGE GRAND CARAVAN. THE CONTACT STATED THAT WHEN THE VEHICLE WAS BEING REFUELED TO CAPACITY, THE FUEL LEVEL INDICATOR WOULD NOT REGISTER THE AMOUNT OF FUEL IN THE VEHICLE. THE VEHICLE WAS TAKEN TO THE DEALER, WHO STATED THAT THEY WOULD HAVE TO REPLACE THE FUEL TANK. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED OF THE FAILURE. THE FAILURE MILEAGE WAS 87,000.

TL* THE CONTACT OWNS A 2004 DODGE GRAND CARAVAN. THE CONTACT STATED THAT FUEL FUMES WERE EMITTED INTO THE VEHICLE. THE CONTACT EXITED THE VEHICLE AND NOTICED A SMALL LEAKAGE. THE VEHICLE WAS TAKEN TO AN INDEPENDENT MECHANIC FOR INSPECTION WHO STATED THAT THE FUEL INJECTOR RAIL NEEDED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOTIFIED AND THEY STATED THAT THERE WAS NO RECALL ON THE VEHICLE. THE FAILURE MILEAGE WAS 47,000.

FUEL LEAK FROM FUEL TANK AT THE FUEL PUMP VERY CLOSE TO THE EXHAUST!!!! *TR

FOR A YEAR OR SO MY WIFE AND I COULD SMELL GASOLINE FUMES IN THE GARAGE AT NIGHT. I CHECKED ENGINE GAS FILLER UNDER CAR, BUT WAS UNABLE TO IDENTIFY SOURCE OF GASOLINE FUMES. FINALLY ABOUT W WEEK AGO THE SMELL OF FUMES WAS STRONGER. I LOOKED UNDER THE CAR AND NOTICED A WET SPOT ON GARAGE FLOOR. I PUT THE CAR ON JACKS CRAWLED UNDER THE CAR AND COULD SEE FUEL OOZING FROM A FITTING ON FUEL LINE THAT WAS CONNECTED TO THE TOP OF THE TANK. THIS FITTING IS SOME SORT OF QUICK DISCONNECT IN WHICH YOU CAN TURN EASILY ON THE WHITE PLASTIC FITTING ON TOP OF THE TANK. WE ARE NOW PARKING AUTO OUTSIDE FEARING THE FUMES COULD IGNITE IN THE GARAGE FROM HOT WATER HEATER. IS THERE A POSSIBLE RECALL ON THIS PROBLEM? *TR

OUR 2004 DODGE GRAND CARAVAN WILL STALL OUT DRIVING DOWN THE ROAD IF YOU FILL THE GAS TANK UNTIL THE GAS PUMP NOZZLES STOPS AUTOMATICALLY. THE ONLY WAY TO STOP THIS IS TO REPLACE THE GAS TANK BECAUSE OF A BAD VALVE IN THE TOP OF THE TANK IN THE EMISSIONS SYSTEM. I FOUND THIS INFORMATION ON LINE. IT HAS DONE IT SEVERAL TIMES AND WE NOW UNDER FILL THE TANK WHICH IS NOT EASY TO DO. *TR

2004 DODGE GRAND CARAVAN STALLS AFTER FILLING UP WITH FUEL, HARD TO START BACK UP, DEALER DID NOT HAVE ANSWER, ALREADY CHANGED GAS CAP AND CAR STILL STALLS ABOUT 80% OF THE TIME AFTER FILLING UP.. *TR

TL*THE CONTACT OWNS A 2004 DODGE GRAND CARAVAN. THE CONTACT STATED THAT EACH TIME SHE ADDED FUEL TO HER VEHICLE IT STALLED. ALL OF THE GEARS ILLUMINATED AND THE BRAKES LOCKED. THE VEHICLE WAS TOWED TO A MECHANIC AND THEN TO THE DEALER BUT THEY COULD NOT DUPLICATE THE FAILURE. THE VEHICLE WAS NOT REPAIRED. THE MANUFACTURER WAS NOT CALLED. THE VIN WAS UNAVAILABLE. THE FAILURE MILEAGE WAS 90,000.

2004 DODGE GRAND CARAVAN FUEL TANK VAPOR FLOAT VENT FAILURE. VEHICLE HAS 59,000 MILES. AFTER FUELING VEHICLE IT WILL STALL INTERMITTENTLY AT STOP SIGNS AND ON OPEN HIGHWAY WITHOUT WARNING, BECAUSE FUEL IS GETTING INTO THE ENGINE AND FLOODING ENGINE OUT VIA THE TANK VENTING VAPOR SYSTEM. WHEN FUELING, A FLOAT IN THE ORVR (ONBOARD REFUELING VAPOR RECOVERY) VALVE IS DESIGNED TO RISES AND SEALS THE TANK VENT CAUSING PRESSURE BUILD, BACKING FUEL UP INTO THE FILL NECK AND SHUTTING IT OFF. THE ORVR IS APPARENTLY NOT SEALING COMPLETELY OR AT ALL, ALLOWING LIQUID FUEL TO PASS INTO THE VENT LINE TO THE VAPOR CANISTER AND THEN ENGINE. THE VALVE IS PLASTIC WELDED TO THE TANK, WHICH REQUIRES THE TANK TO BE REPLACED. MAJOR SAFETY ISSUE BECAUSE THE POWER STEERING SYSTEM STOPS WHEN ENGINE STOPS AND VEHICLE IS NOT ABLE TO BE STEERED WITHOUT THE POWER STEERING AID. VAPOR SYSTEM FAILURE FULLY DESCRIBED AT: HTTP://WWW.JUSTANSWER.COM/QUESTIONS/1OB81-2005-DODGE-CARAVAN-STALLS PRESENTLY ONLY KEEPING TANK FUEL AT A MAXIMUM OF 3/4 FULL TO AVOID FLOODING THE VAPOR VENT SYSTEM. *TR

FOR THE LAST 40,000+ MILES THE VEHICLE ALWAYS STUMBLES OR STALLS AFTER FILLING THE FUEL TANK FULL. WE'RE NOT TALKING ABOUT OVERFILLING, JUST FILLING IT UNTIL THE AUTO SHUT-OFF SHUTS OFF THE FLOW. IT WILL BUCK AND STUMBLE WHEN YOU ARE DRIVING DOWN THE ROAD AND OFTEN DIES WHEN YOU ARE PULLING OUT INTO TRAFFIC. IT HAS STALLED ON MY WIFE WHILE SHE WAS WAITING TO TURN LEFT AT A BUSY INTERSECTION. ONCE RE-STARTED IT RUNS FINE UNTIL THE NEXT FILL-UP. THE DEALER TOLD ME IT IS THE PURGE SOLENOID AND IT WOULD COST $190 TO FIX. THE VEHICLE HAS 92,000 MILES ON IT AND I THOUGHT THAT WAS WELL BELOW THE FEDERAL EMISSIONS WARRANTY AND IT ALSO HAS THE EXTENDED 100,000 MILE WARRANTY. I HAVE NOT HAD IT FIXED YET, BUT JUST AVOID TOPPING OFF THE TANK. THE DATE LISTED BELOW IS ONLY THE MOST RECENT. WE ARE TALKING ABOUT LITERALLY DOZENS OF FAILURES OF THIS SORT -- EVERY SINGLE TIME THE GAS TANK IS FILLED TO THE AUTO-STOP WITHOUT FAIL. THE SERVICE GUY AT THE DEALERSHIP SAID THEY HAVE HAD A NUMBER OF COMPLAINTS OF THIS TYPE ABOUT THIS VEHICLE. *TR

SHORTLY AFTER FILLING UP WITH GAS, I OFTEN EXPERIENCE DIFFICULTY WITH THE VEHICLE. IT SOMETIMES STALLS. IT ACTS UP WITHIN A MINUTE OR TWO BY TRYING TO STALL. I TRY TO GIVE IT AS MUCH GAS AS I CAN AND IT EVENTUALLY STOPS ACTING UP IF IT DOESN'T STALL FIRST. THE DEALER SAYS THEY CANNOT REPLACE THE FUEL FILTER, BECAUSE IT IS PART OF THE WHOLE GAS TANK SETUP. IT IS NOT REPLACEABLE LIKE MOST FUEL FILTERS ARE. IT SEEMS TO ME THAT IT IS THE FUEL FILTER NEEDING TO BE CLEANED. I DO BELIEVE IT IS RUINING MY FUEL PUMP SLOWLY. I AM CONCERNED ABOUT WHEN IT STALLS THAT SOMEONE MAY RUN INTO THE BACK OF ME. *TR

DT: THE CONSUMER STATED THE LOCATION OF THE FUEL TANK CAUSES IT TO BE SUSCEPTIBLE TO DAMAGE AND CAUSE LEAKING WHICH CAN LEAD TO A FIRE HAZARD. *JB