Intermediate Shaft and Dash Seal Removal and Installation: Installation

WARNING: This page is about a different car, the 2005 Suzuki Reno and 2005 Suzuki Forenza. However, it is still accessible from the selected car via links, so may be relevant.

Install the intermediate shaft into the vehicle.

Fig 1: Identifying Intermediate Shaft
Courtesy of SUZUKI OF AMERICA CORP.
Install the dash seal retaining ring with the nuts.
Tighten

Tighten the dash seal retaining ring nuts to 7 N.m (62 lb-in).

Fig 2: Identifying Dash Seal Retaining Ring Nuts
Courtesy of SUZUKI OF AMERICA CORP.

CAUTION: When attaching the upper universal joint, the steering wheel must be placed in the straight-ahead position with the spokes pointing down.
Attach the upper universal joint of the intermediate shaft onto the steering column.
Install the pinch bolt into the upper universal joint on the intermediate shaft and tighten the bolt.
Tighten

Tighten the upper intermediate shaft pinch bolt to 22 N.m (16 lb-ft).

Fig 3: Identifying Upper Pinch Bolt On Universal Joint
Courtesy of SUZUKI OF AMERICA CORP.

CAUTION: When attaching the lower universal joint, the marks on the intermediate shaft and on the stub shaft should line up.
Attach the lower universal joint of the intermediate shaft onto the steering gear stub shaft.

Fig 4: Aligning Marks On Stub Shaft Housing To Ensure Proper Positioning
Courtesy of SUZUKI OF AMERICA CORP.

CAUTION: When installing the lower intermediate shaft pinch bolt, make sure the bolt goes through the universal joint on the side of the stub shaft with the notch. If you have trouble seating the universal joint completely down onto the stub shaft, rotate the steering wheel slightly while pushing down on the universal joint.
Install the bolt into the lower universal joint on the intermediate shaft and tighten the bolt.
Tighten

Tighten the lower intermediate shaft pinch bolt to 22 N.m (16 lb-ft).

Fig 5: Identifying Intermediate Shaft Pinch Bolt
Courtesy of SUZUKI OF AMERICA CORP.