Rack Boot/Tie-Rod Removal and Installation: Installation

WARNING: This page is about a different car, the 2004 Suzuki Vitara. However, it is still accessible from the selected car via links, so may be relevant.

Install new tie-rod lock washer and tie-rod to rack.
Tighten tie-rod ball nut to specified torque.
Tightening torque

Tie-rod ball nut (a): 85 N.m (8.5 kg-m, 61.5 lb-ft)
Bend lock washer (1) (2 places) at the flat part of tie-rod ball nut.

Fig 1: Installing Tie-Rod Lock Washer Tie-Rod
Courtesy of SUZUKI OF AMERICA CORP.
Apply grease to "a" indicated in the figure.

Fig 2: Applying Grease
Courtesy of SUZUKI OF AMERICA CORP.
Position boot properly in grooves of gear case and tie-rod. Check to ensure that boot is free from twist and dent.
Fasten boot with new clamp and clip securely.
Special tool

(A): 09943-55010

Fig 3: Fastening Boot With New Clamp
Courtesy of SUZUKI OF AMERICA CORP.
Install tie-rod end lock nut and tie-rod end to tie-rod. Position lock nut to marking (1) made in removal.
NOTE: When tie-rod was replaced, measure length "a" on removed tie-rod and use it on new replacement tie-rod so as to position lock nut properly.

Fig 4: Positioning Lock Nut To Marking
Courtesy of SUZUKI OF AMERICA CORP.
Install steering gear case referring to "POWER STEERING GEAR BOX ASSEMBLY REMOVAL AND INSTALLATION: ".