96 Caravan Loss of RPM Stalls and Restart

[MADMAX03]

Hey people I hope someone can help me. I have a 1996 Caravan 3.0L and if I am on the highway going and faster then 65 to 70MPH the engine will lose RPM's and start to misfire and I'm unable to give it gas, it just slowly comes to a crawl and stalls. After about 5 minutes or so it will start back up and I good to go. If I stay under 65MPH I don't have any problems. Now a few weeks ago I had my SES light come on and I checked the code 32 EGR. I unpluged the wires and hoses from the EGR & Solenoid and then reset the computer and the light didn't come back on. The first time that this problem happed, the light came on again and using a SnapOn scanner it said Random Misfire. We reset it again and thought that it was just that a Random Misfire. Because the van was running fine we thought it was just a hick up. But then I hit the highway to go home and then it did it again at the same speeds, stalled and 5 min later started up and ran fine. Just wondering if the EGR could cause this, or is it something else like a fuel filter, pick up coil, module, or coil. I don't think it's a fuel problem but I might be wrong. Any help would be awsome. Thanx

[Yatzek]

Hey,

It may be a fuel pump. I had similar problem last month - fixing it was about $1,000

Jack

[hernandez3674]

Circuit Description: FROM my manual:
The ECM operates a vacuum solenoid to control the Exhaust Gas Recirculation (EGR) valve. This solenoid is normally closed. By providing a ground path, the ECM energizes the solenoid, allowing vacuum to reach the EGR valve.
Under certain conditions, when the EGR valve is normally open, the ECM tests the EGR function by de-energizing the EGR control solenoid, blocking vacuum to the EGR valve diaphragm. Without EGR, the system will sense a lean condition and will increase the fuel integrator rate in response. The ECM monitors the amount of fuel delivery increase. If the increase is below a specified value, the ECM will interpret that the test was failed. The failure indicates that closing the EGR valve when it would normally be open does not make a significant change, indicating a problem in the EGR system. The basic purpose of the EGR valve is to recirculate some exhaust gases back through the engine to help reduce combustion temps. It seems strange to introduce exhaust into the air/fuel mixture but if is beneficial. Remove the egr and spray carb cleaner . It will clean the valve but when cleaning it, hold it so the vacuum diaphram is up. Carb cleaner can deteriorate the rubber, plastic or any electrical components. The reason you experienced a mis-fire when trying to maintain a constant speed is the EGR opens at partial throttle by way of vacuum from the engine, when the vacuum diaphram leaks, the engine is pulling extra air into the engine which leans out the mixture and gives you a mis-fire.

[MADMAX03]

Thanx for the input guys. Just to keep you posted my SES light came on againg and it's code 32 (EGR problem). I'm going to replace the EGR valve and see what happens. Thanx again.

[ucurl]

Ok, happened again this past weekend.
1996 Caravan - Stalls out for no apparent reason. When you press gas pedal nothing happens. It appears to happen when the fuel is below half.[SES light on - has been for a while as a result of low compression in one cylinder] can't get past this code to see what else is wrong.

Check this link out regarding Shell Gas additive and Chrysler vehicles between 1996 and 2002
Shell Article Jan 7 2003

I suspect defective fuel pump caused by gas additive. Although it's the ASD relay that we can't seem to find why it shuts down.

Unfortunately, we are ex-Shell employees and still supported them by buying their gas. So I will seek info/answers tomorrow from both Shell & Chrysler.

[MADMAX03]

My van died again and this time I could not get it started. Had it towed and replaced the fuel pump and filter and all is good. Hope this helps. The hole time it was the fuel pump on its way out, and finally it quit. Good luck.

[dodge9696]

Hi Max:

My old username was dodge96 . You responded to my post about the same subject.

A month ago, I had the spark plugs replaced. Last week, after it died again, I had the crankshaft position sensor replaced. No problems so far.

When my mechanic picked up the sensor at a Dodge dealership, their head mechanic said that he never seen this sensor mal-function and suggested check the wire harness, etc.

I had my guy install the sensor anyway.....I don't trust the dealership. Plus from reading this forum, it was only logitical to try the sensor.

How many miles does you van have? Mine has 56k....could a pump go after 56k?

[MADMAX03]

My van had 195K on it. I wouldn't think a fuel pump would go that soon but stranger things have happened. Well you said that it's running fine now, I would just keep driving and not worry about the fuel pump. You can ask your machanic to check your fuel pressure and if that checks out then you should be good to go. Good luck.

[ucurl]

Just a follow-up.
We replaced the Fuel Pump and all seems fine so far.
(crossed fingers)

[dodge9696]

An update......died again.......all three time has been around the same location on the highway.........fuel tank will get below a half of a tank and the trouble begins. This last time I was able to make it to a gas station and filled up.

A couple of questions/remarks........it only happens on the highway, not local driving. Last week the fuel light came on..so I can run it dry driving locally without issues.

It always happens generally in the same area of the highway. Could hills, curves, etc effect the pump? Is it worth it to complain about a pump lasting only 56k miles? And how much did it cost you to replace the pump? Last time, my mechanic said about $500 if I did replace it. Good price?

Thanks for the help

[jarpret]

Hello, I too experience the same problem. It took a while for my mechanic to figure out what is wrong but it finally got fixed. I do not exactly know the part that he replaced but it sure did fixed the misfires. Now my van is in top shape again. I will find out from my mechanic the exact part and give u the P/N. Email me at [email protected] directly if you want to give it a try on your van.

Good luck.