This procedure covers the replacement of the air intake hose assembly on the 2019-2024 Toyota RAV4 with the 2.5L I4 gas engine, connecting the air filter box to the throttle body.

Warnings

Tools required

Parts

• Air intake hose assembly × 1 — Use OEM specification
• Hose clamps (if damaged) × 2 — Use OEM specification

Preparation

1. Park vehicle on level surface and apply parking brake
2. Turn ignition off and remove key
3. Allow engine to cool completely if recently operated
4. Open hood and secure with prop rod

Procedure

1. 1

   Disconnect negative battery cable
   Locate the battery in the engine bay. Using a 10mm socket, loosen the negative terminal clamp bolt and remove the cable from the battery post. Secure cable away from battery terminal to prevent accidental reconnection.
2. 2

   Disconnect mass air flow sensor connector
   Locate the MAF sensor on the air intake tube near the air filter housing. Press the release tab on the electrical connector and carefully pull the connector straight off the sensor. Do not pull on the wiring harness.
3. 3

   Remove air filter housing cover
   Locate the clips securing the air filter housing cover (typically 4-6 clips around the perimeter). Using a flathead screwdriver if necessary, release each clip and lift the cover off. Remove the air filter element and set aside if reusing.
4. 4

   Loosen throttle body clamp
   Locate the hose clamp securing the air intake hose to the throttle body at the engine end. Using a flathead screwdriver or hose clamp pliers, loosen the clamp completely but do not remove it from the hose.
5. 5

   Loosen air filter housing clamp
   Locate the hose clamp at the air filter housing end of the intake hose. Loosen this clamp completely using a flathead screwdriver or hose clamp pliers.
6. 6

   Disconnect PCV hose if equipped
   Check for any PCV or vacuum hoses connected to the air intake tube. If present, use needle-nose pliers to compress the spring clamps and slide them away from the connection points. Carefully pull the hoses off the intake tube nipples.
7. 7

   Remove intake hose assembly
   Grasp the air intake hose firmly and twist slightly while pulling to break the seal at both the air filter housing and throttle body ends. Remove the hose assembly from the engine bay. Inspect both connection points on the vehicle for debris or damage.
8. 8

   Clean connection surfaces
   Using a clean lint-free cloth, wipe the throttle body inlet and air filter housing outlet to remove any dirt, oil, or debris. Inspect the throttle body opening for excessive carbon buildup or contamination.
9. 9

   Install new air intake hose
   Position the new air intake hose assembly, ensuring proper orientation with any vacuum hose connections facing the correct direction. Slide the air filter housing end onto the outlet first, then maneuver the throttle body end into position. Ensure both ends are fully seated onto their respective connections.
10. 10

    Secure clamps
    Tighten the hose clamp at the air filter housing end first, ensuring the hose is fully seated. Then tighten the throttle body end clamp. Verify clamps are positioned over the reinforced bead areas of the hose connections and are snug but not over-tightened.
11. 11

    Reconnect vacuum hoses
    If PCV or other vacuum hoses were disconnected, push them firmly onto the intake tube nipples until fully seated. Slide the spring clamps back into position over the connection points using needle-nose pliers.
12. 12

    Reinstall air filter and housing cover
    Place the air filter element back into the lower housing with the correct orientation (check for directional arrows). Position the housing cover and press down firmly while engaging all clips around the perimeter. Verify all clips are fully secured.
13. 13

    Reconnect MAF sensor
    Push the MAF sensor electrical connector straight onto the sensor until you hear or feel a positive click indicating the locking tab has engaged. Give the connector a gentle tug to verify it is locked in place.
14. 14

    Reconnect battery
    Reattach the negative battery cable to the battery post and tighten the clamp bolt securely with a 10mm socket. Ensure the connection is tight and will not move.

Reassembly

1. Double-check all hose clamps are properly tightened and positioned
2. Verify no tools or parts have been left in the engine bay
3. Ensure all electrical connections are fully seated and locked

Verification

• Start the engine and listen for any air leaks or whistling sounds from the intake system
• Verify engine idles smoothly with no rough running or surging
• Check that no warning lights appear on the dashboard, particularly the check engine light
• Perform a visual inspection of all connections while engine is running to confirm no air leaks
• Test drive vehicle briefly to ensure normal acceleration and throttle response

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