I have a 2003 Dodge Grand Caravan with some fuel related issues:
* Can only fill gas tank a gallon or so at a time until the pump shuts off. You can hear the fuel rise up the filler tube so it sounds like the tank is not venting properly?
* After filling tank, the fuel guage will only read abou 1/4 full then will slooooowly increase (while driving) to max level.
* Loud whistling sound coming from the gas tank on very hot days when driving.
* Starting car after it has been sitting for a few minutes, the engine splutters a little but (maybe 10 seconds or so) and then idles and runs fine after that.

I don't want to taint your diagnosis, but my first though was that the sending unit and/or pump within the tank was messed up. I recall dropping the tank years ago to investigate but for the life of me, I couldn't figure out how to remove the sending unit (and I've done plenty in the past). Is it even possible to remove the unit on this tank or do you have to replace the whole tank???
Thanks for any insight,
-Adam

 

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THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-001-09, DATED
APRIL 15, 2009, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A
COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT
REVISIONS.
SUBJECT:
Hard To Fill With Fuel Or Fuel Nozzle Shuts Off Repeatedly
MODELS:
2004 -2008 (CS) Pacifica
2009 (DS) Ram Truck (1500)
2007 - 2009 (DH) Ram Truck (1500/2500 Pick Up)
2004 - 2009 (DR) Ram Truck (1500 / 2500 Pick Up)
2005 - 2009 (HB) Durango
2007 - 2009 (HG) Aspen
2005 - 2009 (ND) Dakota
2009 (JC) Journey
2007 - 2009 (JK) Wrangler
2007 - 2009 (J1) Sebring (China CKD)
2007 - 2009 (JS) Sebring/Sebring Convertible/Avenger
2006 - 2009 (K1) Cherokee (CKD)
2007 - 2009 (KA) Nitro
2008 - 2009 (KK) Liberty
2008 - 2009 (KK) Cherokee (International Markets)
2005 - 2007 (KJ) Liberty
2005 - 2007 (KJ) Cherokee (International Markets)
2005 - 2009 (LE) 300C/300C Touring (International Markets)
2005 - 2009 (LX) 300/Magnum/Charger
2007 (L2) 300 (China)
2008 - 2009 (LC) Challenger
2004 - 2009 (PT) Chrysler PT Cruiser
NUMBER: 14-001-09 REV. A
GROUP: Fuel
DATE: September 1, 2009
2007 (R2) Caravan/Voyager (CKD)
2005 - 2007 (RG) Chrysler Voyager (International Markets)
2003 - 2007 (RS) Town & Country/Caravan/Voyager
2008 - 2009 (RT) Town & Country/Grand Caravan
2008 - 2009 (RT) Town & Country/Grand Voyager (International
Markets)
2005 - 2006 (TJ) Wrangler
2005 - 2009 (WH) Grand Cherokee (International Markets)
2005 - 2009 (WK) Grand Cherokee
2006 - 2009 (XH) Commander (International Markets)
2006 - 2009 (XK) Commander
NOTE: This bulletin applies to all vehicles equipped with a gasoline engine.
DISCUSSION:
Customer may report that the vehicle is hard to fill with fuel or that the fuel pump nozzle
shuts off repeatedly while trying to fill vehicle.
This customer complaint can occur due to a number of different causes. The fuel tank is
the least likely cause of this condition. The following Diagnostic procedure can be used to
diagnose the issues.
DIAGNOSIS:
1. Is the vehicle a LX/LE/LC/L2?
a. Yes >> proceed to Step #2
b. No >> proceed to Step #4
2. Idle the vehicle 60 to 90 seconds upon stopping.
3. Does tank refill properly?
a. No >> proceed to Step #4
b. Yes >> Inform the customer to idle the vehicle for 60 to 90 seconds upon stopping if
vehicle was driven aggressively. This is due to the fact that on the LX/LE/LC/L2 the
fuel tank is a unique saddle tank design and needs 30 to 60 seconds while the
engine is running to level the fuel in both half's of the fuel tank. Allowing the vehicle
to idle for this amount of time will let the fuel pump transfer fuel to the left side tank,
opening the control valve and allowing normal fuel filling.
4. Disconnect the vapor recirculation tube at the fuel tank.
5. Attempt to refill fuel tank.
6. Does tank refill properly?
a. Yes >> Proceed to Step #7
b. No>> Proceed to Step #11.
7. Reconnect the vapor recirculation tube at the fuel tank.
8. Disconnect the other end of the vapor recirculation tube at the fuel filler tube.
9. Attempt to refill fuel tank.
10. Does tank refill properly?
a. Yes >> Replace fuel filler tube.
b. No >> Replace the vapor recirculation tube.
11. Disconnect the control valve to EVAP canister tube at the fuel tank.
14-001-09 REV. A -2-
12. Reconnect the vapor recirculation tube at the fuel tank.
13. Does tank refill properly?
a. No >> Replace Fuel Tank.
b. Yes >> Proceed to Step #14.
14. Reconnect the control valve to EVAP canister tube at the fuel tank.
15. Disconnect the control valve to EVAP canister tube at the EVAP canister.
16. Attempt to refill fuel tank.
17. Does tank refill properly?
a. Yes >> Blockage is in the EVAP Canister, or ESIM, or Clean air hose (ESIM vent
hose), or filter. Diagnose appropriately.
b. No >> Replace the control valve to EVAP canister tube.
POLICY:
Information Only