This procedure covers the removal and replacement of ignition coil packs on the 2019-2024 Toyota RAV4 with the 2.5L I4 gasoline engine.

Warnings

Tools required

Parts

• Ignition coil pack × 1 — 90919-02260 (OEM) or equivalent

Preparation

1. Ensure engine is completely cool to the touch
2. Park vehicle on level surface and engage parking brake
3. Disconnect negative battery terminal and wait 90 seconds
4. Open hood and locate engine cover on top of engine

Procedure

1. 1

   Remove engine cover
   Remove the plastic engine cover by pulling upward firmly on the cover. It is retained by rubber grommets that require moderate force to release. Set the cover aside.
2. 2

   Identify faulty coil pack
   Locate the ignition coils on top of the engine. There are four coils, one for each cylinder. Identify which coil pack needs replacement based on diagnostic trouble codes or testing results. Coils are numbered 1-4 from left to right (passenger side to driver side) when facing the engine from the front of the vehicle.
3. 3

   Disconnect electrical connector
   Press down on the locking tab of the electrical connector on the target coil pack and pull the connector straight up and off the coil. Do not pull on the wiring harness itself.
4. 4

   Remove coil pack retaining bolt
   Use a 10mm socket with extension to remove the single bolt securing the ignition coil to the valve cover. Keep the bolt in a safe location for reinstallation.
   Torque spec

   Ignition Coil Bolts8 Nm (6 lb-ft)
5. 5

   Extract coil pack
   Grasp the coil pack firmly and pull straight up with a steady, firm motion. The coil may require moderate force to break the seal with the spark plug boot. Twist slightly while pulling if resistance is encountered. Do not rock side to side as this can damage the boot or spark plug ceramic.
   ⚠If excessive force is required, stop and verify the retaining bolt was fully removed. Forcing the coil can break the spark plug.
6. 6

   Clean spark plug well
   Use compressed air or a clean brush to remove any debris, dirt, or oil from around the spark plug well opening. Ensure no debris falls into the cylinder. Inspect the spark plug well for oil accumulation, which may indicate a valve cover gasket leak.
7. 7

   Inspect spark plug (optional)
   If replacing only the coil and not the spark plug, inspect the visible portion of the spark plug for damage, cracks, or excessive wear. If spark plug replacement is needed, use a spark plug socket to remove it at this time. Apply anti-seize compound to new spark plug threads before installation and torque to specification.
   Torque spec

   Spark Plugs - Aluminum Head20 Nm (15 lb-ft)
8. 8

   Prepare new coil pack
   Inspect the new coil pack boot for damage and ensure it is clean. Apply a thin coat of dielectric grease to the inside of the spark plug boot if desired. This helps with future removal and moisture protection.
9. 9

   Install new coil pack
   Align the new coil pack with the spark plug well and push down firmly until the coil is fully seated on the spark plug. The coil should sit flush against the valve cover. You should feel the boot make positive contact with the spark plug terminal.
10. 10

    Install and torque retaining bolt
    Insert the coil pack retaining bolt and hand-tighten first. Use a torque wrench with 10mm socket to tighten the bolt to the specified torque. Do not overtighten as this can crack the coil housing.
    Torque spec

    Ignition Coil Bolts8 Nm (6 lb-ft)
11. 11

    Reconnect electrical connector
    Push the electrical connector onto the coil pack terminal until you hear and feel a positive click, indicating the locking tab has engaged. Gently tug on the connector to verify it is securely locked in place.
12. 12

    Reinstall engine cover
    Align the engine cover grommets with the mounting posts on the valve cover and push down firmly until all grommets are fully seated.
13. 13

    Reconnect battery
    Reconnect the negative battery terminal. The vehicle may require a brief relearning period for idle control.

Reassembly

1. Ensure all electrical connectors are fully seated and locked
2. Verify engine cover is properly installed on all mounting grommets
3. Double-check that all tools and parts have been removed from engine bay

Verification

• Start the engine and verify it runs smoothly without misfires
• Check that the check engine light does not illuminate or that previous misfire codes have cleared
• Listen for any unusual noises from the ignition system
• Use a scan tool to verify no active ignition-related diagnostic trouble codes are present
• Perform a test drive to confirm normal engine performance under load

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