Rack and Pinion Disassembly and Assembly: Assembly

NOTE: Coat all the seals with power steering fluid to ensure proper sealing.

Install the rack, the bulkhead inner cylinder and the bulkhead inner cylinder retaining ring.

Fig 1: Installing Retaining Ring
Courtesy of SUZUKI OF AMERICA CORP.

CAUTION: To prevent the inner tie rods from loosening, use Loctite(R) 242 (or equivalent) on both inner tie rod connections to secure them to the rack shaft.

NOTE: The right and left inner tie rods are unequal in length. Be sure to install the correct inner tie rod on the proper side of the power steering gear.
Firmly seat the inner tie rods against the rack and tighten both ends simultaneously.
Tighten

Tighten the inner tie rods to 100 N.m (74 lb-ft).

Fig 2: Tighten Inner Tie Rods
Courtesy of SUZUKI OF AMERICA CORP.
Push the plastic retainer back onto the connection between the inner tie rod and the power steering gear rack.

Fig 3: Installing Plastic Retainer
Courtesy of SUZUKI OF AMERICA CORP.
Install the dust boot.

Fig 4: Installing Dust Boot
Courtesy of SUZUKI OF AMERICA CORP.
Install the cylinder end dust boot retaining clamps with the installer KM-J-22610.

Fig 5: Installing The Cylinder End Dust Boot Retaining Clamps
Courtesy of SUZUKI OF AMERICA CORP.
Install the tie rod end boot retaining clamps.

Fig 6: Installing The Tie Rod End Boot Retaining Clamps
Courtesy of SUZUKI OF AMERICA CORP.
Reposition the adjusting nut to the marks on the inner tie rod and install the outer tie rod by twisting it onto the inner tie rod.

Fig 7: Installing The Outer Tie Rod
Courtesy of SUZUKI OF AMERICA CORP.
Perform a front toe adjustment.
Tighten the adjusting nut.
Tighten

Tighten the outer tie rod adjusting nut to 64 N.m (47 lb-ft).
Install the rack bearing assembly into the rack and pinion steering assembly. Refer to Rack Bearing Disassembly and Assembly .
Install the valve and pinion assembly into the rack and pinion steering assembly. Refer to Valve and Pinion Disassembly and Assembly .
Install the rack and pinion steering assembly into the vehicle. Refer to Rack and Pinion Assembly Removal and Installation .