Thread: How To: Replace the Fuel Pump Relay Module
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Old Jul 29, 2009 | 09:05 AM
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Joined: Oct 2008
Posts: 41
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From: Brisbane Queensland Australia
Post How To: Replace the Fuel Pump Relay Module
Firstly, a big thanks to everyone who has contributed to discovering and resolving this issue. It saved me a lot of heart ache that’s for sure and saved me from taking it to the local stealership to *laughs* diagnose the problem and then have them *laughs even harder* fix it.

I wanted to put our “Mystery No Start Issue” in a quick idiots picture guide for us all in a concise step by step process.

If this has already been posted my apologies, but here is hopefully something that will help those of us suffering from the same problem.

Diagnosis: As has been comprehensively covered in previous posts if your Crossfire won’t start, stops randomly in inconvenient places for no reason, has all the dash lights illuminated but no effort from the starter motor to kick the engine into life when you turn the key...chances are you need to replace the fuel pump relay control module. We have been told the reason why this needs to be replaced is that over time heat from the engine bay destroys the solder connections within the module. Thus commonly when the car ‘cools down’ it will start again.

Equipment needed:

·10mm Spanner to undo the negative battery terminal
 ·5 minutes, at the most, of your time
 ·A fuel pump relay control module.

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I got mine from Mercedes Benz Australia part no: A 170 545 03 05. There is an equivalent Chrysler part but Mercedes were cheaper. Be prepared, this will set you back some cash mine cost AUD $549.95 express posted to me (US $434 roughly). I probably could have got this cheaper if I sourced it from the States but I didn’t have the luxury of time.


Step One:
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This is where you’ll be for the next couple of minutes. Disconnect the negative battery terminal and remove the lid on the fuse box.

Step Two:
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Locate the module and pull it out by slipping it out of the grasp of the two clasps either side of the module.

Step Three:
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Remove the five wire harness heads from the module using care not to pull on any of the wires. Once you’ve pulled them all out push them into their respective locators on the new module and place module back into the box from whence it came.

Step Four:
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Job Done! Replace the lid and re-connect the negative battery terminal. Note, you will get the ESP/BSP warning light come on because of disconnecting the battery terminal. Clear it by turning the steering wheel all the way to the left then all the way to the right and then centring it.

Take it for a test drive and wait another four or five years till you have to do it again!
 
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