Suzuki XL-7

On certain vehicles, the tension adjuster pulley for the drive belt which operates the power steering pump and air conditioner compressor (if equipped) has an outer portion that is made of plastic.  Repeated heat stress can cause the plastic material to deteriorate and pieces of the pulley can break off.  Broken pieces of the pulley can get caught between the pulley and the drive belt, causing the drive belt to come off and resulting in the driver needing increased effort to steer the vehicle.  This situation could result in a crash causing property damage, personal injury or death.  Correction: Dealers will replace the power steering pump drive belt tension adjuster pulley.

On certain vehicles, under ambient temperatures below -25 degrees Celsius, moisture can freeze in the fuel pressure regulator.  As a result, fuel system pressure may increase at the time of engine start up, causing fuel loss at the fuel pipe/fuel hose connection.  Fuel loss in the presence of an ignition source could result in a fire.  Correction:  For 1999-2000 model year vehicles, dealers will (1) replace the fuel pressure regulator & vacuum hose and change the system routing to accommodate use of a higher surge tank attachment location that will prevent water from being sucked into the fuel pressure regulator, and (2) replace the fuel delivery hose and replace the hose clamp with an improved clamp.  For 2001 and later model year vehicles, dealers will only replace the fuel pressure regulator & vacuum hose and change the system routing as described above.  Note: This recall supersedes recall 2001032.

On certain vehicles, the accelerator cable casing cap that is attached to the firewall can crack due to extended exposure to forces from the accelerator cable and insufficient long-term durability of the plastic casing cap.  If the casing cap becomes cracked, movement of the inner accelerator cable through the cap can cause the inner accelerator cable to become frayed.  If the inner accelerator cable becomes frayed, it can stick during vehicle operation.  Correction:  Dealer will replace the accelerator cable assembly.

On certain vehicles, the ignition system wiring harness could rub against the intake manifold during vehicle operation, possibly causing abrasion damage to the harness.  Damage to the wiring harness may create a short in the ignition circuit, which can cause the ignition fuse to blow and the engine to stop running.  Correction:  Dealer will inspect the wiring harness and repair any damage.  A protector plate will be installed to prevent future wiring harness damage.

On certain vehicles, the windshield may not be properly secured to the vehicle body due to insufficient adhesion between paint applied during the second-stage painting process and paint applied during final-stage painting.  If the windshield is not properly secured to the vehicle body, it may separate from the vehicle during a collision resulting in ejection of unbelted occupants and severe injury or death.  Correction: Dealers will affect repairs.