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Home >> Toyota >> 1996 >> RAV4 4D Utility, AWD, Automatic >> Repair and Diagnosis >> Engine Performance >> Remove, Overhaul & Install >> Engine Controls - Remove/Install/Overhaul >> Fuel System >> Fuel Rails & Fuel Injectors >> Removal
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Fuel Rails & Fuel Injectors: Removal

  1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE  under FUEL SYSTEM. Remove coolant reservoir from near air cleaner case.
  2. Disconnect necessary electrical connectors, wires and hoses for removal of air cleaner upper cap assembly. Disconnect air intake hose at throttle body. Remove air cleaner upper cap assembly, air intake hose and air filter. Remove lower air cleaner case assembly.
  3. Remove power steering reservoir for access to valve cover. Remove necessary components and engine wiring covers for access to valve cover. Remove nuts, grommets, valve cover and gasket. Place grommets in order for reassembly reference, as grommets should be installed in original location to prevent oil leakage.
  4. Remove throttle body from air intake chamber. See THROTTLE BODY  under FUEL SYSTEM. Remove distributor with spark plug wires. See DISTRIBUTOR  under IGNITION SYSTEM.
  5. Remove necessary brackets and engine wire for access to fuel rail and fuel injectors. See Figure. Note location of electrical connectors on fuel injectors for reassembly reference. Disconnect electrical connectors from fuel injectors.
  6. Disconnect vacuum hoses at EGR valve. Loosen EGR pipe at EGR valve. Remove EGR valve with EGR pipe. Remove mounting bolts from fuse/relay box located at driver's side front strut tower. Move fuse/relay box from strut tower.
  7. Remove air assist hose from intake manifold and air assist system. See Figure. Remove fuel inlet hose-to-fuel filter union bolt from top of fuel filter. Fuel inlet hose remains attached to fuel rail.
    CAUTION: Use care when removing fuel injectors from cylinder head, as not to drop fuel injector.
  8. Remove fuel rail-to-cylinder head bolts. Remove fuel rail from fuel injectors. Remove fuel injectors from cylinder head. Remove spacers from cylinder head. Remove "O" rings, insulator and grommet from fuel injector. See Figure.
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