Dodge Caravan Fuel Heater Issues Causing Engine Stalls

Had a similar issue with my 2012 Dodge Grand Caravan. Being somewhat experienced with diesel engine maintenance, those symptoms sounded familiar, especially the power loss and rough idle. The fuel system was showing similar warning signs, unstable performance and increased fuel consumption. Took it to my regular workshop where they diagnosed a faulty cable connection to the fuel filter heater. The connection had corroded over time, affecting the entire fuel system efficiency. The repair involved replacing the wiring harness and checking the fuel line connections. Total cost was 95€ for parts and labor. After the fix, fuel efficiency improved significantly and the cold start issues disappeared completely. Before suggesting anything specific though, could you share: Current mileage on your vehicle, Any recent fuel system maintenance, Exact error code showing, Weather conditions when problems occur, Any other warning lights on dashboard These details would help confirm if your issue matches what I experienced. A proper diagnosis is crucial since similar symptoms can sometimes point to different fuel system problems in diesel engines.

Just had my regular service at 53852 KM. The cold start problems have become more frequent since then. When I cleared the error code it came back as P0380. The stalling happens mostly at idle, and the power loss is noticeable when accelerating. The diesel engine struggles to maintain steady RPMs, affecting overall fuel efficiency. My fuel consumption has increased by about 3 liters per 100km. No other warning lights are showing on the dashboard, and the engine temperature stays normal. This unstable performance really concerns me, especially since these issues started appearing right after a routine maintenance check.

Good that you provided those details, the P0380 code matches exactly what I experienced with my Caravan. This error specifically relates to the glow plug heating circuit, which ties into our initial discussion about the fuel filter heater system. After my repair, I tracked my fuel consumption closely and saw it drop back to normal within one tank. Your 3L/100km increase matches the pattern I noticed before the fix. The idle stalling issue and power loss during acceleration cleared up immediately after the repair too. Since your issues started after routine service, have the workshop check if the fuel filter was properly bled after replacement. Air in the fuel lines can cause similar symptoms. In my case, they found both the wiring issue and some air pockets in the fuel system. The normal engine temperature reading is actually a good sign, it suggests the problem is isolated to the fuel delivery system rather than something more serious in the engine itself. Based on the matching symptoms and error code, I strongly recommend having the complete fuel filter heater circuit checked, including all wiring connections. The fix should be relatively straightforward and cost-effective, similar to what I paid.

Thanks for the detailed response. Called the workshop and scheduled an inspection for next week. They confirmed the P0380 code typically indicates issues with the glow plug/fuel filter heater system, matching what you described. The service advisor mentioned they would check for air in the fuel lines since the problems started after maintenance. Really hoping this fixes the rough idle and power loss issues. The constant engine stalling at traffic lights has become quite frustrating. Will update once they diagnose the exact problem with the fuel system. If the repair cost stays around 100€ as you mentioned, that would be manageable. Just want my van back to normal fuel consumption and steady performance, especially during these cold starts. The explanation about air pockets in the fuel line makes sense given the timing of these issues. Fingers crossed its just a wiring problem or trapped air rather than a major fuel system overhaul.