Rack and Pinion Assembly Removal and Installation: Installation

Install the rack and pinion assembly on the crossmember. The steering gear must be in a straight-ahead position, and the steering wheel spokes must be vertical and pointing to the left. Align the marks on the shafts to ensure proper positioning. Seat the stub shaft into the intermediate shaft.

Fig 1: Aligning The Marks On The Shafts
Courtesy of SUZUKI OF AMERICA CORP.
Install the bolts and nuts on the steering gear mounting bracket.

Fig 2: Installing The Bolts And Nuts On The Steering Gear Mounting Bracket
Courtesy of SUZUKI OF AMERICA CORP.

Tighten

Tighten the steering gear mounting bracket bolts and nuts to 60 N.m (44 lb-ft).
Install the return line into the clip on the crossmember.
Tighten

Tighten the return line clip bolt to 8 N.m (71 lb-in).
On vehicles equipped with a manual transaxle, position the transaxle center bracket in place and install the bolts securing the bracket to the engine and the transaxle.
Tighten

Tighten the transaxle center bracket-to-transaxle bolts and the transaxle center bracket-to-engine bolt to 80 N.m (59 lb-ft).
On vehicles equipped with an automatic transaxle, install the transaxle center bracket. Refer to REMOVAL & INSTALLATION .
Install the crossmember.
Connect the tie rod ends to the strut assembly.
Install the outer tie rod nuts.

Fig 3: Installing The Outer Tie Rod Nuts
Courtesy of SUZUKI OF AMERICA CORP.

Tighten

Tighten the outer tie rod nuts to 50 N.m (37 lb-ft).
Install the lower intermediate shaft pinch bolt.

Fig 4: Installing The Lower Intermediate Shaft Pinch Bolt
Courtesy of SUZUKI OF AMERICA CORP.

Tighten

Tighten the lower intermediate shaft pinch bolt to 25 N.m (18 lb-ft).
Connect the power steering gear fluid inlet and outlet pipe.

Fig 5: Connecting The Power Steering Gear Fluid Inlet And Outlet Pipe
Courtesy of SUZUKI OF AMERICA CORP.

Tighten

Tighten the steering gear inlet and outlet pipe fitting to 28 N.m (21 lb-ft).
Perform a front toe adjustment. Refer to TOE-IN ADJUSTMENT .
Install the wheels.
Lower the vehicle.
Do a straight-ahead check. Refer to Straight-Ahead Check .
CAUTION: When adding fluid or making a complete fluid change, always use power steering fluid DEXRON(R)-II or III or equivalent. Failure to use the proper fluid will cause hose and seal damage and fluid leaks.
Refill the power steering system and check for leaks. If leaks are found, correct the cause of the leak and bleed the system. Refer to Power Steering System Description .
Connect the negative battery cable.