P/S Gear Box Assembly Removal and Installation: Installation

WARNING: This page is about a different car, the 2003 Suzuki XL-7 and 2003 Suzuki Grand Vitara. However, it is still accessible from the selected car via links, so may be relevant.

Reverse removal procedure for installation of steering gear box, noting the following points.

After confirming that front tire is in straight position, install steering gear box to body temporarily. Next, with tie-rod end installed to knuckle, set rack in position close to neutral. Then obtain the neutral state by aligning match marks (1) on pinion shaft (3) and steering gear case (2) and insert steering lower joint into pinion shaft.

Fig 1: Aligning Match Marks On Pinion Shaft

Courtesy of SUZUKI OF AMERICA CORP.

CAUTION: Be sure to confirm that steering wheel and front tires (wheels) are in straight position when inserting steering lower joint into steering pinion shaft.

If a plug was put to disconnected pipe when removing steering gear box, remove that plug before reconnecting pipe.
Use specified torque as given below.
Tightening torque

Steering lower shaft bolt (a): 25 N.m (2.5 kg-m, 18.5 lb-ft)

Gear box high pressure pipe union bolt (b): 35 N.m (3.5 kg-m, 25.5 lb- ft)

Gear box cylinder pipe flare nut (c): 25 N.m (2.5 kg-m, 18.0 lb- ft)

Gear box mounting bolt (d): 55 N.m (5.5 kg-m, 40.0 lb-ft)

Gear box low pressure pipe union bolt (e): 40 N.m (4.0 kg-m, 29.0 lb-ft)

Fig 2: Tightening Nuts & Bolts
Courtesy of SUZUKI OF AMERICA CORP.
After installation, be sure to fill specified power steering fluid and bleed air.
Check toe setting. Adjust as required. Refer to SPECIFICATIONS & PROCEDURES for Grand Vitara or SPECIFICATIONS & PROCEDURES for XL-7 .