Chrysler Crossfire 2004-2008 Electric Fuel Pump Replacement Guide
Everything you need to know about replacing the unique external fuel pump on your 2004-2008 Chrysler Crossfire.
- The Crossfire uses a German-engineered external fuel pump from its Mercedes-Benz platform; part quality is critical.
- Bosch is the highly-recommended, OEM-quality brand for this part; avoid economy brands if possible to prevent repeat failures.
- Always check the Relay Control Module (RCM) for bad solder joints first, as it can mimic fuel pump failure.
- Replace the fuel filter at the same time as the pump to ensure the longevity of the new part.
Understanding Your Crossfire's Fuel System
Before buying a new fuel pump for your 2004-2008 Chrysler Crossfire, it's important to understand its unique design. Your car is built on a Mercedes-Benz R170 platform, the same as the SLK320. This means many parts, including the fuel pump, are German-engineered. The fuel pump is located externally, under the car near the passenger-side rear wheel, mounted in a bracket next to the fuel filter. This is good news for replacement, as it doesn't require dropping the fuel tank.
Common Symptoms of a Failing Fuel Pump
A failing fuel pump can cause a range of problems, from annoying to leaving you stranded. Here are the most common signs:
- Engine Cranks, But Won't Start: The most definite sign of a dead fuel pump is when the engine turns over but never fires up because it's not getting fuel.
- Long Cranking Time: If the engine takes several seconds longer than usual to start, the pump may be weak or a check valve in the system could be failing, causing fuel pressure to bleed off.
- Engine Stalling: The engine may stall unexpectedly, especially when it's warm or under load like going up a hill. It might restart after cooling down for a few minutes.
- Hesitation or Power Loss: You may feel the car stutter, bog down, or lose power when you accelerate.
- Whining Noise: A noticeable high-pitched whine or hum from the rear of the car is a classic sign of a fuel pump motor working too hard and nearing the end of its life.
Check This First!
The Relay Control Module (RCM), located in the engine bay's passenger-side fuse box, is a known weak point. Bad solder joints inside the RCM can cut power to the fuel pump, perfectly mimicking a pump failure. Before replacing the pump, inspect the RCM or have a mechanic 🎬 Watch this step-by-step guide to troubleshooting the Relay Control Module. test for power at the pump's electrical connector when the key is turned. This can save you from replacing a perfectly good part.
Choosing the Right Aftermarket Fuel Pump
Since your Crossfire uses a Mercedes-designed part, quality matters. A cheap, unreliable pump is not worth the savings when it can leave you stranded. The job is simple enough that you don't want to do it twice. Here’s a breakdown of the available brands.
Brand Quality Tiers
- Top Tier (OEM Quality): Bosch is widely considered the original equipment manufacturer (OEM) for the Crossfire's fuel system. For reliability and peace of mind, Bosch is the most recommended brand by owners and mechanics. It is the safest choice and worth the extra cost.
- Mid-Tier (Quality Aftermarket): Delphi is a well-known OEM supplier for many car brands and offers good quality parts. While generally reliable, some recent forum discussions suggest their quality can be inconsistent compared to Bosch. It's a solid second choice if Bosch is unavailable.
- Economy Tier (Budget-Focused): Brands like URO Parts, AutoBest, and US Motor Works fall into this category. URO Parts specializes in European cars but has a reputation for being hit-or-miss. These brands offer a lower price point, but the trade-off may be a shorter lifespan and lower-quality materials. Consider these only if budget is the primary concern and you accept the potential risk of earlier failure.
Pro Tip: Always replace the fuel filter when you replace the fuel pump. A clogged old filter can strain a new pump, causing it to fail prematurely. The parts are located next to each other, so it adds very little labor.
🎬 See how to replace both the fuel filter and pump.Cost of Replacing a Chrysler Crossfire Fuel Pump
| Part Type | Estimated Cost | Notes |
|---|---|---|
| New Aftermarket Pump | $95 - $343 | Price depends heavily on brand quality, with Bosch at the high end and economy brands at the low end. |
| New OEM (Mopar) Pump | $400 - $550+ | This is the dealer part, which is typically a rebranded Bosch pump at a higher price. |
| Shop Labor | $200 - $350 | Expect 1.5 to 2.5 hours of labor at an independent shop. |
Frequently Asked Questions (FAQ)
Are there any recalls on the Crossfire fuel pump?
No. Searches of the NHTSA database show no safety recalls specifically for the electric fuel pump on the 2004-2008 Chrysler Crossfire. Recalls you may find are for airbags on the Crossfire or for fuel pumps on other Chrysler models with different engines.
Is this a DIY job?
Yes, for a moderately skilled person. The pump is easy to access once the car is safely raised on jack stands. You will need basic hand tools, hose clamps, and a way to safely catch spilled fuel. 🎬 Watch this complete walkthrough for testing and replacing your pump. The most difficult part is often removing the old, stuck-on fuel hoses. Always disconnect the battery and have a fire extinguisher nearby when working with fuel.
Do I need to buy the whole assembly?
For the Crossfire, you typically buy just the fuel pump motor itself. It sits in a reusable metal bracket along with the separate fuel filter. This is different from in-tank pumps that are often sold as a complete module with the sending unit and housing.
Why did my new fuel pump fail so quickly?
If a replacement pump fails, there are two common causes. First, the issue may have been the Relay Control Module (RCM) all along, not the pump. Second, not replacing a clogged fuel filter puts a heavy strain on the new pump, which can cause it to burn out. Lastly, using a low-quality economy brand can lead to premature failure.
Helpful Videos
Technical Specifications
OEM Part Numbers: 5102594AA
External, frame-mounted electric fuel pump. Requires simultaneous replacement of the external fuel filter. Electrical connections use 7mm and 8mm nuts.
We Have This Part in Stock
The information in this article is provided for general reference and educational purposes only. Vehicle specifications, procedures, and part compatibility can vary by production date, trim level, and region. Always consult your vehicle's factory service manual and verify part numbers before purchasing or performing repairs. Safety-critical components such as airbags, seat belts, and braking systems should be installed by a qualified professional.
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