2018 ALFA ROMEO STELVIO

FUEL SYSTEM, GASOLINE:DELIVERY:FUEL PUMP

Chrysler (FCA US, LLC) is recalling certain 2017-2019 Alfa Romeo Giulia and 2018-2019 Alfa Romeo Stelvio vehicles. The fuel pump may fail, which can result in a loss of fuel flow and loss of drive power.

Risk: A loss of drive power increases the risk of a crash.

AIR BAGS:FRONTAL

Chrysler (FCA US, LLC) is recalling certain 2017-2024 Alfa Romeo Giulia, 2018-2025 Alfa Romeo Stelvio, 2019-2023 Fiat 500X, Jeep Renegade, and 2024 Fiat 500E vehicles. A seat belt buckle switch sensor may be improperly connected, preventing the front seat air bag from deploying as intended.

Risk: A front seat air bag that does not deploy as intended can increase the risk of injury in a crash.

SERVICE BRAKES, HYDRAULIC

Chrysler (FCA US, LLC) is recalling certain 2017-2020 Alfa Romeo Giulia and 2018-2020 Alfa Romeo Stelvio vehicles equipped with carbon ceramic matrix brakes. During certain driving maneuvers, the brake system may exert an excessive clamp force that may fracture the rotor, decreasing the brake performance.

Risk: An unexpected decrease in brake performance increases the risk of a crash.

ELECTRICAL SYSTEM: INSTRUMENT CLUSTER/PANEL

Alfa Romeo (FCA US LLC) is recalling certain 2018-2019 Giulia and Stelvio vehicles. The Body Control Module (BCM) may indicate an inaccurate fuel level that displays higher than the actual amount.

Risk: The vehicle may be operated without enough fuel in the tank causing a stall, increasing the risk of a crash.

SERVICE BRAKES, HYDRAULIC:ANTILOCK/TRACTION CONTROL/ELECTRONIC LIMITED SLIP:CONTROL UNIT/MODULE

FCA US LLC (Alfa Romeo) is recalling certain 2018-2019 Alfa Romeo Stelvio and 2017-2019 Giulia vehicles. The Brake System Module (BSM) software may prevent the driver from disabling the Adaptive Cruise Control (ACC) after the traction control system detects a specific wheel slip.

Risk: The driver's inability to deactivate the ACC can increase the risk of crash.

ENGINE AND ENGINE COOLING:COOLING SYSTEM:HOSES/LINES/PIPING/FITTINGS

Chrysler (FCA US LLC) is recalling certain 2018-2019 Alfa Romeo Stelvio Quadrifoglio vehicles. The engine cooling hose may have inadequate webbing material allowing a coolant leak.

Risk: A loss of coolant can cause the engine to overheat and the vehicle to stall, increasing the risk of a crash.

ENGINE AND ENGINE COOLING:ENGINE

Chrysler (FCA US LLC) is recalling certain 2017-2018 Alfa Romeo Giulia and 2018 Alfa Romeo Stelvio vehicles, equipped with 2.0L engines. These engines may misfire causing the catalytic converter to overheat, possibly resulting in damage to the nearby wiring and engine components.

Risk: Heat damage to the engine compartment wiring or components can increase the risk of a fire or it can cause an engine stall, increasing the risk of a crash.

EQUIPMENT:ELECTRICAL

Chrysler (FCA US LLC) is recalling certain 2018 Alfa Romeo Stelvio vehicles. Water may leak into the body control module and its connectors, causing corrosion. This corrosion can cause illumination of one or more malfunction indicator lamps, a loss of windshield wiper function, a loss of exterior lighting, a loss of horn function and/or unintended turn signal activation.

Risk: Electrical malfunctions such as windshield wipers that may not work in the rain and lights that may not work at night increase the risk of a crash.

STRUCTURE:BODY:HATCHBACK/LIFTGATE

Chrysler (FCA US LLC) is recalling certain 2018 Alfa Romeo Stelvio vehicles. Water may Leak into the wiring connectors for the rear liftgate and the liftgate-opening switch, causing corrosion.

Risk: Corrosion at the connectors may cause the liftgate to unintentionally open while moving at speeds of less than 3 miles per hour, allowing cargo to fall out of the vehicle, creating a road hazard and increasing the risk of a crash.

VISIBILITY:WINDSHIELD WIPER/WASHER:MOTOR

Chrysler (FCA US LLC) is recalling certain 2018 Alfa Romeo Stelvio vehicles. The software for the wiper motor may incorrectly interpret the wiper motor as overheating, limiting the windshield wipers to operating only at the low-speed setting. As such, these vehicles fail to comply with the requirements of Federal Motor Vehicle Safety Standard (FMVSS) number 104, "Windshield Wiping and Washing Systems."

Risk: Limited wiper function can reduce the driver's visibility, increasing the risk of a crash.

FUEL SYSTEM, GASOLINE

The contact owns a 2018 Alfa Romeo Stelvio. The contact stated that the instrument cluster was inoperable. The vehicle was taken to an unknown local dealer, and it was confirmed that there was no warranty coverage on the vehicle for the failure. The dealer informed the contact about a seat belt recall that was completed, but the initial failure was not repaired. The contact stated that after refueling, the fuel light illuminated two days later. The contact stated that the vehicle also stalled while driving. The vehicle was not repaired. The manufacturer was contacted, but no assistance was provided. The failure mileage was approximately 44,000.

SEAT BELTS

The contact owns a 2018 Alfa Romeo Stelvio. The contact stated that the instrument cluster was inoperable. The vehicle was taken to an unknown local dealer, and it was confirmed that there was no warranty coverage on the vehicle for the failure. The dealer informed the contact about a seat belt recall that was completed, but the initial failure was not repaired. The contact stated that after refueling, the fuel light illuminated two days later. The contact stated that the vehicle also stalled while driving. The vehicle was not repaired. The manufacturer was contacted, but no assistance was provided. The failure mileage was approximately 44,000.

ELECTRICAL SYSTEM: INSTRUMENT CLUSTER/PANEL

The contact owns a 2018 Alfa Romeo Stelvio. The contact stated that the instrument cluster was inoperable. The vehicle was taken to an unknown local dealer, and it was confirmed that there was no warranty coverage on the vehicle for the failure. The dealer informed the contact about a seat belt recall that was completed, but the initial failure was not repaired. The contact stated that after refueling, the fuel light illuminated two days later. The contact stated that the vehicle also stalled while driving. The vehicle was not repaired. The manufacturer was contacted, but no assistance was provided. The failure mileage was approximately 44,000.

ELECTRICAL SYSTEM

I own a 2018 Alfa Romeo Stelvio (VIN: [XXX] ) with approximately 102,000 miles. The vehicle recently experienced an electrical issue caused by a failed ground strap — a known problem in these vehicles that is widely reported by other owners. After the vehicle became inoperable, I observed smoke and visible signs of burned or heat-damaged wiring in multiple areas under the hood, including ground wires not located near the main strap and crumbling insulation on the ABS wiring in the front wheel wells. The vehicle was towed to an authorized Alfa Romeo dealership, where the ground strap was replaced. However, the dealer did not inspect or document the other visibly damaged wiring, despite my specific request and description of the safety issue. They claimed the vehicle showed no error codes and was safe to drive. My concern is that the failed ground strap caused additional electrical damage to safety-critical components like the ABS system, which may result in electrical fire, loss of braking, or other failures. Alfa Romeo appears to have updated the design of the replacement ground strap (now rubber-insulated), which suggests they are aware of the issue, but they have not issued a recall or TSB. I am filing this report to document the issue and request that NHTSA investigate. I believe this is a systemic problem that affects vehicle safety, and that Alfa Romeo and its dealerships are failing to address it adequately. INFORMATION REDACTED PURSUANT TO THE FREEDOM OF INFORMATION ACT (FOIA), 5 U.S.C. 552(B)(6)

UNKNOWN OR OTHER

Odometer fraud car titled with 63789 when ecu reflect 81111 in computer of car and dealer selling it

ENGINE

I had my radiator fail, lost all fluid and had to be towed. The car has 73,000 miles on it, is well maintained and garage kept. Alfa has sent the dealerships a Service Bulletin item about the issue, but never contacted the consumers about fixing it proactively. My son broke down on a highway, was able to limp the vehicle to a parking lot where the car had to be towed. The repair was done by Alfa and cost almost $3,000 No issues showed up prior. Once the fail happened the car was

ENGINE

The car never showed signs of an issue, I got on the car with my two children, when I attempted to start the car. The engine started smoking and smelled like burned plastic. We got out of the car, the smoke went on for about 15-30 seconds. After that the car did not start. The engine's wiring was charred. I was informed by the dealer a ground strap failed. This ground strap is exposed to the elements at the bottom of the engine and it's prone to corrode, rendering it useless and causing the electrical wiring to overheat and potentially start a fire.

ELECTRICAL SYSTEM

The car never showed signs of an issue, I got on the car with my two children, when I attempted to start the car. The engine started smoking and smelled like burned plastic. We got out of the car, the smoke went on for about 15-30 seconds. After that the car did not start. The engine's wiring was charred. I was informed by the dealer a ground strap failed. This ground strap is exposed to the elements at the bottom of the engine and it's prone to corrode, rendering it useless and causing the electrical wiring to overheat and potentially start a fire.

FUEL/PROPULSION SYSTEM

Similar to Investigation PE24000, my 2018 Alfa Romeo Stelvio fuel pump failed during low speed driving in a parking garage. The car was rendered inoperable and would not restart. The engine failed while driving and only due to my low speed and lack of traffic at that moment, I was able to maneuver the car safely to a stop. The dealership identified the issue as relating to the fuel pump, vey similar to the Low Pressure Fuel Pump Assembly Failure investigation PE24000 run by investigator Arnaldo Torres Diaz. Just wanted to provide the information to encourage Fiat Chrysler to expand this repair into a recall for Alfa Stelvio models that also share the Alfa Giulia 2.0 liter four cylinder engine.

UNKNOWN OR OTHER

My 2018 Alfa Romeo Stelvio was diagnosed by a certified Alfa Romeo dealer with a major engine defect involving coolant mixing with oil. The diagnosis revealed internal failure likely stemming from the oil cooler or head gasket, and the parts estimate alone was over $17,000 — not including labor. The dealer confirmed the issue but stated no recalls apply and denied warranty coverage. The car showed early signs like minor overheating and coolant loss, but no clear warning lamps or check engine lights until the issue escalated. This defect significantly increases the risk of engine failure, overheating, or loss of power while driving — posing a serious safety concern. I have since discovered multiple other owners reporting the exact same problem in Alfa Romeo forums and consumer complaint sites. The dealer has confirmed the issue but refused support. I believe this may reflect a broader design flaw affecting many vehicles and should be investigated for potential recall.

POWER TRAIN

My 2018 Alfa Romeo Stelvio was diagnosed by a certified Alfa Romeo dealer with a major engine defect involving coolant mixing with oil. The diagnosis revealed internal failure likely stemming from the oil cooler or head gasket, and the parts estimate alone was over $17,000 — not including labor. The dealer confirmed the issue but stated no recalls apply and denied warranty coverage. The car showed early signs like minor overheating and coolant loss, but no clear warning lamps or check engine lights until the issue escalated. This defect significantly increases the risk of engine failure, overheating, or loss of power while driving — posing a serious safety concern. I have since discovered multiple other owners reporting the exact same problem in Alfa Romeo forums and consumer complaint sites. The dealer has confirmed the issue but refused support. I believe this may reflect a broader design flaw affecting many vehicles and should be investigated for potential recall.

ENGINE

My 2018 Alfa Romeo Stelvio was diagnosed by a certified Alfa Romeo dealer with a major engine defect involving coolant mixing with oil. The diagnosis revealed internal failure likely stemming from the oil cooler or head gasket, and the parts estimate alone was over $17,000 — not including labor. The dealer confirmed the issue but stated no recalls apply and denied warranty coverage. The car showed early signs like minor overheating and coolant loss, but no clear warning lamps or check engine lights until the issue escalated. This defect significantly increases the risk of engine failure, overheating, or loss of power while driving — posing a serious safety concern. I have since discovered multiple other owners reporting the exact same problem in Alfa Romeo forums and consumer complaint sites. The dealer has confirmed the issue but refused support. I believe this may reflect a broader design flaw affecting many vehicles and should be investigated for potential recall.

FUEL SYSTEM, GASOLINE

The contact owns a 2018 Alfa Romeo Stelvio. The contact stated that while driving at an undisclosed speed, the vehicle lost motive power. The message "Electronic Acceleration Control Disabled" was displayed. The contact pulled over and waited a while before restarting the vehicle. The vehicle was taken to the dealer, where it was determined that the low-pressure fuel pump had failed. The contact was informed that the low-pressure fuel pump and module needed to be replaced. The vehicle was not yet repaired and remained with the dealer. The manufacturer was not made aware of the failure. The failure mileage was approximately 13,500.

ELECTRICAL SYSTEM

Car wouldn’t start, was able to jump start and take to dealer. Front ground straps at both steering knuckles have been shorted and melted leaving exposed wires. New headlamp to dash harness is needed due to complete short. This has caused electrical issues causing ABS/Power steering/auto stop lights to randomly come on and off. Unable to drive in case car stops operating while driving due to shortage. Alfa Romeo dealer has confirmed this issue. Lights did not appear until after this occurred. After researching online this appears to be a common issue reported among people owning this 2018 Alfa Romeo Stelvio due to the harness/straps/wiring melting and corroding due to design flaw. Quoted $6,450 for total repair.

ELECTRICAL SYSTEM

Ground wire to starter had corroded and broke into. Wife tried to start the vehicle and saw smoke coming up out of the hood. This caused the main wiring harness to burn and wires to fall apart. The wires run from the front wheels up into the engine bay and throughout vehicle. The vehicle could have caught fire or could have possibly caused the brakes to fail while driving. I contacted Alfa Cares but they would not help cover cost (estimated approximately $9,000). This is not only a safety issue but a non maintenance for the customer issue. This isn’t a scheduled maintenance and is a product failure by the manufacturer. This issue should be a recall for both issues.This also caused all warning lights to come on the dash including steering, ABS, and about four other warning lights. Please consider this issue as a recall as Alfa doesn’t seem to care enough to take care of it and before someone gets hurt. The issue has been noted by an independent repair shop as well as an Alfa Romeo certified mechanic.