Rack and Pinion Assembly

Install the rack gear and rack gear stopper to the rack gear housing.
Install the circlip.

Fig 1: Installing Rack Gear And Rack Gear Stopper To Rack Gear Housing
Courtesy of SUZUKI OF AMERICA CORP.
Install the pinion shaft ball bearing.

Fig 2: Installing Pinion Shaft Ball Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Install the pinion shaft, seal and needle bearing.

Fig 3: Installing Pinion Shaft Seal And Needle Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Install the snap ring and dust cover (Rubber).

Fig 4: Installing Snap Ring And Dust Cover
Courtesy of SUZUKI OF AMERICA CORP.
Install the pinion lock nut, snap ring and dust cover.
Tighten

Tighten the pinion lock nut to 30 N.m (22 lb-ft).

Fig 5: Installing Pinion Lock Nut Snap Ring And Dust Cover
Courtesy of SUZUKI OF AMERICA CORP.
Coat the rack bearing, the adjuster spring, and the adjuster plug with lithium-based grease and install them into the housing.
With the rack centered, turn the adjuster plug clockwise until a torque of 7 N.m (62 lb-in) is obtained, then back it off by 30 to 40 degrees. Check the pinion torque. Maximum pinion preloaded torque is 1 N.m (9 lb-in).
Thread the locknut on the adjuster plug and tighten it.
Tighten

Tighten the adjuster plug locknut to 75 N.m (56 lb-ft) while holding the adjuster plug stationary with the rack guide spring cap wrench J-42459 or with a 19 mm alien wrench.

Fig 6: Installing Adjuster Plug Lock Nut Adjuster Plug Adjuster Spring And Rack Bearing
Courtesy of SUZUKI OF AMERICA CORP.
Install the inner tie rod.
Tighten

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

Fig 7: Installing Inner Tie Rod
Courtesy of SUZUKI OF AMERICA CORP.
Install the dust boot and retaining clamps.

Fig 8: Installing Dust Boot And Retaining Clamps
Courtesy of SUZUKI OF AMERICA CORP.
Install the outer tie rod end and lock nut.
Tighten

Tighten the outer tie rod end lock nut to 64 N.m (47 lb-ft).

Fig 9: Installing Outer Tie Rod End And Lock Nut
Courtesy of SUZUKI OF AMERICA CORP.