NHTSA Complaint #10638968 — 2007 DODGE GRAND CARAVAN

AFTER FUELING THE VEHICLE, PULLING OUT FROM THE GAS STATION, THE VAN STALLS VIOLENTLY: LOSES POWER, LURCHES & SURGES. THIS HAS BECOME INCREASINGLY SEVERE, MOST RECENTLY NEARLY CAUSING A COLLISION WHEN THE VAN STALLED OUT AS WE WERE LEAVING THE GAS STATION IN HEAVY TRAFFIC. THE PROBLEM IS THE VAPOR/LIQUID SEPARATOR VALVE LOCATED AT THE TOP OF THE FUEL TANK. THE VALVE IS DESIGNED TO PREVENT LIQUID FUEL FROM ENTERING THE CHARCOAL CANISTER/EMISSIONS SYSTEM. WHEN THE VALVE FAILS, LIQUID GAS CAN ENTER THE LINE AND FILL THE CHARCOAL CANISTER. AFTER REFUELING THE PCM ON THE VEHICLE DETECTS A CHANGE IN FUEL LEVEL. THEN, WHEN THE ENGINE MEETS CERTAIN TEMPERATURE AND DRIVING CRITERIA, THE PCM ISSUES A PURGE COMMAND TO THE CHARCOAL CANISTER TO REMOVE THE STORED GAS VAPORS. IT?S AT THAT POINT THAT ALL THE LIQUID GAS IN THE LINE GETS SUCKED INTO THE CHARCOAL CANISTER. THE PCM EXPECTS TO SEE GAS VAPORS ENTERING THE INTAKE MANIFOLD AND IT IS PREPARED TO ADJUST AIR/FUEL MIXTURES TO COMPENSATE. HOWEVER, IT IS NOT PREPARED TO SEE LIQUID GAS COMING INTO THE INTAKE. THAT?S WHAT CAUSES THE ENGINE TO STALL. UNFORTUNATELY, THE ONLY FIX IS TO REPLACE THE ENTIRE GAS TANK. CHRYSLER DOES NOT SELL THE VAPOR/LIQUID VALVE AS A SEPARATE UNIT. WE ARE NOW AT NEARLY 100,000 MILES, AND THE PROBLEM PERSISTS AND CONTINUES TO GET MORE SEVERE. I HAVE CALLED DODGE, BUT THEY SAY THERE IS NO EXTENDED WARRANTY ON THE FUEL TANK/EVAPORATION CANISTER. *TR