Alfa Romeo Giulia Recalled Over Potential Fuel Leak From Fuel Line Sensor Housing

6 months, 2 weeks ago - 6 May 2024, autoevolution

A small number of Giulia sedans have been produced for the US market with a fuel line sensor housing prone to cracking. The suspect vehicles were sold as 2021 models, and their production dates are March 23, 2021 through April 28, 2021.

FCA US LLC says that a fuel leak may result in sudden loss of motive power, increasing the risk of a crash. The worst-case scenario would be for the dino juice to contact the exhaust manifold or turbo, increasing the risk of a fire. According to the Auburn Hills-based automaker, the suspect fuel supply tube bears part number 68619503AA and was manufactured by Hutchinson Poland Sp. z o.o.

Stellantis Europe S.p.A. received a warranty claim alleging fuel in the engine compartment on October 6 last year. Two months later, the European division received the second warranty claim related to the recall condition, prompting the automaker to investigate these claims with the supplier. Turns out FCA US previously recalled 11,419 units of the Giulia and Stelvio in 2021 for the same problem, and that Stellantis Europe and the supplier failed to identify all suspect fuel supply tubes at the time.

The most curious thing is that FCA US LLC did not explain why the Giulia and Stelvio could leak in the area of the fuel line sensor housing. The automaker did not give an explanation this time around either, but does offer a clue in the form of the remedy component. More specifically, a properly molded fuel line sensor housing. Otherwise put, Hutchinson Poland is to blame for both the first and second recalls.

On this occasion, the recall population comprises 261 units of the Giulia, which is the Italian brand's first production vehicle underpinned by the Giorgio platform. The Ferrari-infused architecture is joined by the Ferrari-derived V6 of the Quadrifoglio, which produces a little over 500 ponies in both the Giulia Quadrifoglio and Stelvio Quadrifoglio.

It's not clear whether the suspect fuel line sensor housing is exclusive to the 2.0-liter turbo four-cylinder engine or the Quadrifoglio-exclusive V6 as well. Because it's nigh-on impossible for an owner to determine when their vehicle was assembled, the easiest way to tell whether your Giulia is affected or not is to run the VIN on Alfa Romeo's website.

Owner notifications will begin June 19, the day Alfa Romeo dealers will also be informed about said recall. Following the 2024 model year, the Giulia Quadrifoglio and Stelvio Quadrifoglio will be discontinued from the North American lineup in preparation for zero-emission replacements. Because the next-generation Stelvio will debut in the second half of 2025 and the Giulia in the first half of 2026, the 2025 model year Stelvio and Giulia for North America will be 2.0-liter turbo only.

Similar to Stellantis-owned Lancia, the Alfa Romeo brand intends to become fully electric in a few short years. Alfa Romeo should have a 100-percent electrified lineup by 2027, while Lancia is targeting 2026. Emphasis on electrified because both Alfa Romeo and Lancia have recently unleashed next-generation vehicles (i.e., the Junior and Ypsilon) with both mild-hybrid and full-electric setups.

At press time, you can order a Giulia stateside at $43,340 for the rear-drive Sprint or $2,000 more for the all-wheel-drive Sprint. The better-selling Stelvio is $45,950 and $47,950, respectively.