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96 Dodge Grand Caravan LE 3.8


Little history as might be relevant.

Prior to this issue, the vans fuel gage sometimes wouldn't work correctly and if it got near low it wouldn't start. Though if gage wasn't working correctly, maybe it was out.

Then one of the fuel pump nipples started spraying a fine spray of gas, so I replaced it with a Delphi fuel pump and new filter.

Since then if it gets low (at least according to fuel gage around 1/4 tank) it acts violently and throws P0300 code. Adding fuel resolves issue, little rough at first but returns to normal and the check engine light goes away.

Is this a bad fuel pump or could there be something else in play?
 

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The P0300 code is coming from the actual violent act it's experiencing when the tank is low.

The cause of this could be fuel related. Once it gets down to a 1/4 tank it begins sucking air. Not being supplied sufficient fuel would cause it to misfire.
It's mentioned the Delphi pump was installed. Was a new sock on it and was it pushed on correctly. Was just the pump changed or the entire unit? Was it installed correctly and definitely hitting the bottom of the tank? The actual pump can be changed. When done like this new hoses between the pump and the delivery tube should be used. They could have a crack in them or a clamp leaking. It the pump was changed this way was the steel line looked over for signs of cracking? Is the gauge itself accurate? Upon removal/disassembly/installation of the pump. If the sending unit's float isn't handled carefully, it can be bent out of calibration. Even a new complete unit, could have an issue from the factory.
!/4 of a tank is the key. You want to look in that area of the fuel pump assembly.

It sounds as though your gauges themselves could be the issue too. Maybe your gauge is saying 1/4 but in actuality you ARE empty. Your instrument panel sounds like it could suffer from the "cold solder joint" issue. I would make sure you don't have this issue first and foremost. A fuel gauge measure resistance with ground. If you have a ground issue at the gauge cluster, you will have false readings. Pull the cluster. Remove the circuit board and flip it over to reflow the solder on the main plugs connections.

Fill the tank from 1/4. How many gallons did it take? How many is the tank? Compare the numbers. If it's the amount of your tank, the gauge is wrong.
 
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