Safety Recall Y91 Fuel Leak – 2020-2021 Alfa Romeo Stelvio & Giulia

November 12, 2021 NHTSA CAMPAIGN NUMBER: 21V878000

Fuel Line Sensor Housing May Leak

A fuel leak may cause an engine stall, increasing the risk of a crash. A fuel leak also increases the risk of fire in the presence of an ignition source.

 

NHTSA Campaign Number: 21V878

Manufacturer Chrysler (FCA US, LLC)

Components FUEL SYSTEM, GASOLINE

Potential Number of Units Affected 11,419

 

Summary

Chrysler (FCA US, LLC) is recalling certain 2020-2021 Alfa Romeo Stelvio, and Alfa Romeo Giulia vehicles. The fuel line sensor housing may crack and leak fuel.

 

Remedy

Dealers will inspect and replace the fuel line sensor housing, as necessary, free of charge. Owner notification letters were mailed on January 11, 2022. Owners may contact FCA US, LLC customer service at 1-800-853-1403. FCA US, LLC’s number for this recall is Y91.

 

Notes

Owners may also contact the National Highway Traffic Safety Administration Vehicle Safety Hotline at 1-888-327-4236 (TTY 1-800-424-9153), or go to www.nhtsa.gov.

 

Check if your Vehicle has a Recall

 

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New Safety Recall Advanced Communication – Y91

FCA US LLC (FCA US) has announced a safety recall on certain 2020 and 2021 Model Year (GU) Alfa Romeo Stelvio and (GA) Alfa Romeo Giulia vehicles.

 

REASON FOR THIS SAFETY RECALL

Some of the above vehicles may have been equipped with a fuel line sensor housing that may crack and leak fuel. The fuel line sensor fuel leak may cause fuel starvation of the engine. Fuel starvation may result in an unexpected loss of motive power, which can cause a vehicle crash without prior warning. In rare circumstances, if the leaked fuel comes in contact with an ignition source, a fire could occur A vehicle fire can result in increased risk of occupant injury and/or injury to persons outside the vehicle, as well as property damage.

 

SERVICE ACTION

FCA US will conduct a voluntary safety recall to inspect the fuel line sensor housing, and replace if needed. The remedy for this condition is not currently available. Dealers will be notified of the launch of this safety recall by way of established communication methods. This recall is estimated to launch in 1st Quarter of 2022.

 

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Revision 1 January 2022

Dealer Service Instructions for:

Safety Recall Y91 / NHTSA 21V-878 Front Fuel Delivery Line

NOTE: Added part number detail and verification step in re-installation procedure.

Remedy Available

2020 – 2021	(GA)	Alfa Romeo Giulia
	(GU)	Alfa Romeo Stelvio

 

NOTE:  This campaign applies only to the above vehicles equipped with a 2.0L and 2.9L engine.

NOTE:  Some vehicles above may have been identified as not involved in this recall and therefore have been excluded from this recall.

IMPORTANT:  Some of the involved vehicles may be in dealer new vehicle inventory.  Federal law requires you to complete this recall service on these vehicles before retail delivery.  Dealers should also consider this requirement toapply to used vehicle inventory and should perform this recall on vehicles in for service.  Involved vehicles can be determined by using the VIP inquiry process.

 

Subject

The fuel sensor housing on about 12,057 of the above vehicles may crack and leak fuel. The fuel line sensor fuel leak may cause fuel starvation of the engine. Fuel starvation may result in an unexpected loss of motive power, which can cause a vehicle crash without prior warning. In rare circumstances, if the leaked fuel comes in contact with an ignition source, a fire could occur A vehicle fire can result in increased risk of occupant injury and/or injury to persons outside the vehicle, as well as property damage.

 

Repair

Replace the front fuel delivery line on all of the above vehicles involved.

Section: A. Giulia and Stelvio 2.0L – Front Fuel Delivery Line Removal

Section: B. Giulia and Stelvio 2.0L – Front Fuel Delivery Line Installation

Section: C. Stelvio/Giulia 2.9L – Front Fuel Delivery Line Removal

Section: D. Stelvio/Giulia 2.9L – Front Fuel Delivery Line Installation

 

Alternate Transportation

Dealers should attempt to minimize customer inconvenience by placing the owner in a loaner vehicle if the vehicle must be held overnight.

 

Parts Information

Part Number	Description
68400640AA	Line, Front Fuel Delivery (Stelvio 2.9L Engine)
68323454AA	Line, Front Fuel Delivery (Giulia 2.9L Engine)
68364747AA	Line, Front Fuel Delivery (Giulia AWD or Stelvio AWD/RWD 2.0L Engine)
68361423AA	Line, Front Fuel Delivery (Giulia RWD 2.0L Engine)
68163848AB	1 Gallon Antifreeze/Coolant (MS-12106)

 

Parts Return

No parts return required for this campaign.

 

Special Tools

No special tools are required to perform this service procedure.

 

Service Procedure

A. Giulia and Stelvio 2.0L – Front Fuel Delivery Line Removal 

1. Perform the fuel pressure release procedure below.

 

2. Open the deck lid.

 

3. Rotate the knobs ¼ turn on the right side trim panel and remove the panel (Figure 1).

 

4. Remove the fuse box cover (Figure 2).

 

5. Locate the T-10 fuel pump relay and remove it and set aside (Figure 3).

 

6. Start vehicle several times until all the pressure in the fuel distribution manifolds has discharged and the vehicle will not start.

 

7. Lift up the compartment load floor and press the release button and disconnect the negative battery cable from the post. If equipped with an Intelligent Battery Sensor (IBS), disconnect the IBS connector (Figure 4).

 

NOTE: If the deck lid closes while the battery is  disconnected, the rear seat may need to be removed to gain access to the auxiliary trunk release latch located in the luggage compartment.

 

8. If equipped: Remove the engine compartment cross support bar (Figure 5).

 

9. Using a small blade screwdriver or equivalent pry on the engine cover caps to access the engine cover fasteners and remove the cover (Figure 6).

 

10. Unlatch and disconnect the Powertrain Control Module (PCM) electrical connectors (Figure 7).

 

11. Remove the PCM fasteners and remove the PCM and the bracket.

 

12. Using a trim tool disconnect the wiring harness retaining clip attached to the engine compartment.

 

13. If equipped: Using a small blade screw driver or equivalent release the power distribution cover (Figure 8).

 

14. If equipped: Unfasten and disconnect the right side B+ cable from the power distribution center (Figure 9).

 

15. Relieve the coolant system pressure by slowly rotating the coolant overflow bottle cap.

 

16. Disconnect the de-gass coolant line at the coolant reservoir (Figure 10).

 

18. Disconnect the fuel pressure/temperature sensor electrical connector (Figure 11).

 

19. Disconnect the fuel line from the rubber grommets.

 

20. Unlatch the upper fuel line by pulling up on the tab, squeeze both sides of the fuel line latch to release the fuel line (Figure 12).

 

21. Unlatch the lower fuel line lock and press on the bottom of the lock to release the fuel line, remove the fuel line and DISCARD (Figure 13).

 

22. Proceed to section: B. Giulia and Stelvio 2.0L – Front Fuel Delivery Line Installation.

 

 B. Giulia and Stelvio 2.0L – Front Fuel Delivery Line Installation

1. Install the NEW front fuel supply line, connect the quick connectors and engage the lock.

 

NOTE: Verify fuel line is fully seated and lock is engaged by slightly pulling on the fuel line and making sure it stays connected.

 

2. Connect the electrical connection for the fuel temperature-pressure sensor.

 

4. Engage the wiring in the retaining clips.

 

5. Connect the de-gass quick connector to the coolant reservoir.

 

7. If equipped: Reconnect the B+ cable to the power distribution center (Figure 9).

 

6. Install the Powertrain Control Module (PCM) and PCM mounting bracket and secure the fasteners.

 

7. Reconnect the PCM electrical connectors (Figure 7).

 

8. Align and install the engine cover and fasten the screws securely (Figure 6).

 

9. If equipped: Install the support bar and tighten the fasteners securely (Figure 5).

 

10. Lift up the compartment load floor and press the release button and connect the negative battery cable to the post. If equipped with an Intelligent Battery Sensor (IBS), connect the IBS connector (Figure 4).

 

NOTE: after disconnecting the 12V battery at the end of the operations, check the date and time on the display and update them if necessary.

 

11. Install the T-10 fuel pump relay in to the fuse box cavity.

 

12. Install the fuse box cover.

 

13. Align the trim panel to the right side trim opening and rotate the knobs ¼ turn (Figure 1).

 

14. Close the tailgate.

 

15. Start the engine and check for any fuel leaks.

 

16. Return the vehicle to the customer, for state of California residents complete the Proof of Correction Form.

 

17. Complete Proof of Correction Form for California Residents:

This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program.  Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration.

 

C. Stelvio/Giulia 2.9L – Front Fuel Delivery Line Removal

1. Perform the fuel pressure release procedure below:

a. Open the tailgate

b. Remove the compartment load floor.

c. Remove the fuse box lid.

d. Remove the F83 fuse (Figure 14).

 

2. Start vehicle several times until all the pressure in the fuel distribution manifolds has discharged and the vehicle will not start.

 

3. Press the release button and disconnect the negative battery cable from the post. If equipped with an Intelligent Battery Sensor (IBS), disconnect the IBS connector (Figure 15).

 

NOTE: If the deck lid closes while the battery is disconnected, the rear seat may need to be removed to gain access to the auxiliary trunk release latch located in the luggage compartment.

 

4. Remove the belly pan.

 

5. Remove the left front wheel and the front wheel well housing splash shield.

 

6. Open the coolant drain valve and partially drain the cooling system until the right coolant reservoir is empty (Figure 16).

 

NOTE: Do not open the drain valve if the engine is hot as there is a danger of scalding.

 

7. Remove the engine cover.

 

8. Remove the air cleaner housing and air inlet ducts.

 

9. Remove the coolant supply hose quick connector retainer and disconnect the hose.

 

10. Remove the degassing hose quick connector.

 

11. Remove coolant reservoir fasteners and remove the reservoir.

 

12. If equipped: Disconnect the left fender electronic control module electrical connectors (Figure 18).

 

13. Disconnect the electrical connector from the fuel temperature-pressure sensor (Figure 19).

 

14. Disconnect the quick connectors and remove the front fuel supply line complete with fuel pressure-temperature sensor and DISCARD the line.

 

15. Proceed to section: D. Stelvio/Giulia 2.9L – Front Fuel Delivery Line Installation.

 

D. Stelvio/Giulia 2.9L – Front Fuel Delivery Line Installation

1. Place the NEW front fuel supply line in the rubber grommets and connect the quick connectors and lock the tabs.

 

NOTE: Verify fuel line is fully seated and lock is engaged by slightly pulling on the fuel line and making sure it stays connected.

 

2. Connect the electrical connector to the fuel temperature -pressure sensor.

 

3. Install the coolant reservoir and secure the fasteners.

 

4. Connect the coolant supply and degass hoses.

 

5. Reconnect the electronics control module electrical connectors.

 

6. Install the air cleaner and ducts.

 

7. Install the left front wheel housing splash shield and the left front tire.

 

8. Install the belly pan.

 

9. Install the engine cover.

 

10. Install the F83 fuse in to the fuse box cavity.

 

11. Install the fuse box cover.

 

12. Install the compartment load floor.

 

13. Connect the negative battery cable to the post. If equipped with an Intelligent Battery Sensor (IBS), connect the IBS connector.

 

NOTE: after disconnecting the 12V battery at the end of the operations, check the date and time on the display and update them if necessary.

 

14. Align and install the trim panel to the right side trim opening and rotate the knobs ¼ turn to lock in place.

 

15. Close the tailgate.

 

16. Fill the cooling system by following the procedure below:

a, Open the bleed screws on the primary and secondary radiators (Figure 20).

b. Add coolant to the reservoir until fluid starts to come out of the two bleed screws. Tighten the bleed screws.

c. Install the coolant reservoir cap.

d. Start and run the engine, if there is a noticeable drop in the level in the supply tank at this point, turn off the engine and open the cap very carefully and add fluid to the full mark on the reservoir.

 

17. Check for any fuel or coolant leaks.

 

18. Return the vehicle to the customer, for state of California residents complete the Proof of Correction Form.

 

Complete Proof of Correction Form for California Residents:

This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement Program.  Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053) and supply it to vehicle owners residing in the state of California for proof that this recall has been performed when they renew the vehicle registration.

 

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Chronology :

• On October 7, 2021, Alfa Romeo Supplier Quality became aware of a potential fuel leak to the engine bay fuel bundle at the Cassino Assembly plant In Italy.
• On October 11, 2021, the Cassino Assembly plant began a sorting operation by the connector production date.
• On October 18, 2021, the supplier identified six suspect batches delivered to production operations.
• As of November 4, 2021, FCA US LLC (“FCA US”) is aware of one customer assistance record, eight warranty claims, and zero field reports potentially related to this issue for all markets with dates of receipt ranging from March 1, 2021, to September 27, 2021.
• As of November 4, 2021, FCA US is aware of zero accidents and zero injuries potentially related to this issue for all markets.
• On November 4, 2021, FCA Italy S.p.A. determined, through the Vehicle Regulations Committee, to conduct a voluntary safety recall of the affected vehicles.

 

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4 Affected Products

Vehicles

MAKE	MODEL	YEAR
ALFA ROMEO	GIULIA	2020-2021
ALFA ROMEO	STELVIO	2020-2021

 

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10 Associated Documents

Defect Notice 573 Report

RCLRPT-21V878-5616.PDF 215.599KB

RCLRPT-21V878-5616

 

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Manufacturer Notices(to Dealers,etc) – NSRAC re New Safety Recall Advanced Communication Y91 FCA US LLC (FCA US) has announced a safety recall on certain 2020 and 2021 Model Year (GU) Alfa Romeo Stelvio and (GA) Alfa Romeo Giulia vehicles

RCMN-21V878-5112.pdf 97.666KB

RCMN-21V878-5112

 

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Manufacturer Notices(to Dealers,etc) – NSRAC Final re New Safety Recall Advanced Communication Y91 FCA US LLC (FCA US) has announced a safety recall on certain 2020 and 2021 Model Year (GU) Alfa Romeo Stelvio and (GA) Alfa Romeo Giulia vehicles.

RCMN-21V878-2176.pdf 100.102KB

RCMN-21V878-2176

 

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ISSUED Owner Notification Letter(Part 577)

RCONL-21V878-0716.pdf 515.145KB

RCONL-21V878-0716

 

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Remedy Instructions and TSB

RCRIT-21V878-4556.pdf 3222.564KB

RCRIT-21V878-4556

 

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Recall Acknowledgement

RCAK-21V878-1512.pdf 645.213KB

RCAK-21V878-1512

 

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Remedy Instructions and TSB

RCRIT-21V878-3011.pdf 3222.903KB

RCRIT-21V878-3011

 

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Recall Quarterly Report #1, 2022-1

RCLQRT-21V878-6734.PDF 211.147KB

RCLQRT-21V878-6734

 

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Recall Quarterly Report #2, 2022-2

RCLQRT-21V878-6038.PDF 211.248KB

RCLQRT-21V878-6038

 

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Recall Quarterly Report #3, 2022-3

RCLQRT-21V878-8143.PDF 211.333KB

RCLQRT-21V878-8143

 

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Latest Recalls Documents

https://www-odi.nhtsa.dot.gov/acms/cs/documentList.xhtml?docId=21V878&docType=RCL

 

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Last update on 2022-11-20 / Affiliate links / Images from Amazon Product Advertising API

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