Rack Boot / Tie-Rod Removal and Installation: Installation

WARNING: This page is about a different car, the 2004 Suzuki XL-7 and 2004 Suzuki Grand 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
1. Tie-rod ball nut (a): 90 N.m (9.0 kg-m, 65.0 lb-ft)
Bend lock washer at 2 places (1) as shown.

Fig 1: Bending Lock Washer
Courtesy of SUZUKI OF AMERICA CORP.
Apply grease to "A" indicated in the figure.

Fig 2: Identifying Lube Point
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.
Clamp boot with clip and wire. Wire should be new and should go around the boot twice.
Pull its both ends together by screwdriver or such and make sure that the wire won't be crossed. Then twist the ends several times, the twisted ends should be bent in the circumferential direction.

Fig 3: Clamping Boot With Clip & Wire
Courtesy of SUZUKI OF AMERICA CORP.
Install tie-rod end lock nut and 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. Refer to P/S Gear Box Assembly Removal and Installation .