Steering Rack Plunger Removal and Installation: Installation

Reference: STEERING RACK PLUNGER INSPECTION: ELECTRIC TYPE 

1. Install plunger (1), new O-ring (6), washer (4), spring washers (5) and spring (2) as shown.
   NOTE: Do not wipe off grease previously applied to new plunger.
2. Apply sealant to rack damper screw (3) and tighten them as follows.
   1. Tighten rack damper screw to 25 N.m (2.5 kgf-m, 18.0 lbf-ft).
   2. Loosen damper screw until 180°.
   3. Retighten rack damper screw to 3.9 N.m (0.39 kgf-m, 3.0 lbf-ft).
   4. After tightening rack damper screw to specified torque, turn it back by 10° or less.

      "A": Water tight sealant 99000-31250 (SUZUKI Bond No. 1207F) 

      Tightening torque 

      Rack damper screw (a): Tighten 25 N.m (2.5 kgf-m, 18.0 lbf-ft) and loosen 180° and then tighten 3.9 N.m (0.39 kgf-m, 3.0 lbf-ft) and turn it back by 10° or less by the specified procedure  .

      Fig 1: Identifying Steering Rack Plunger Components

      Courtesy of SUZUKI OF AMERICA CORP.
3. Pinion rotation torque should be checked with rack position centered.

   Also, check if rack as a whole moves smoothly.

   Special Tool 

   (A): 09944-18220 

   Tightening torque 

   Rotation torque of pinion (a): 2.2 N.m (0.22 kg-m, 1.5 lbf-ft) 

   Fig 2: Checking Rotation Torque Of Pinion

   Courtesy of SUZUKI OF AMERICA CORP.
4. After adjustment, tighten lock nut to specified torque with holding damper screw at the position.

   Tightening torque 

   Steering rack damper lock nut: 60 N.m (6.0 kg-m, 43.5 lbf-ft)