This procedure covers the location, removal, and replacement of the cooling fan relay in the engine compartment relay/fuse box on a 2019-2024 Toyota RAV4 with the 2.5L I4 gas engine.

Warnings

Tools required

Parts

• Cooling fan relay × 1 — 90987-02028 or equivalent

Preparation

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

Procedure

1. 1

   Disconnect battery negative terminal
   Using a 10mm socket, loosen the nut on the negative battery terminal and remove the cable. Position it away from the battery post to prevent accidental contact during the repair.
2. 2

   Locate engine compartment relay box
   The primary relay/fuse box is located on the driver's side of the engine compartment, near the front corner adjacent to the battery. It is a black rectangular box with multiple covers.
3. 3

   Remove relay box cover
   Press the tabs on both sides of the relay box cover and lift upward to remove. The relay diagram is printed on the underside of the cover for reference. Set the cover aside in a clean location.
4. 4

   Identify cooling fan relay location
   Refer to the relay diagram on the cover or in the owner's manual. The cooling fan relay is typically labeled as 'COOLING FAN' or 'FAN RELAY' and is positioned in the upper section of the relay box. It is a square relay with 4 or 5 pins depending on configuration.
5. 5

   Test existing relay (optional)
   If diagnosing a cooling fan issue, you can test the relay using a multimeter to check for continuity between terminals when energized. Refer to factory service information for specific terminal identification and resistance values.
6. 6

   Remove cooling fan relay
   Grip the relay firmly and pull straight upward with steady pressure. If the relay is difficult to remove, use needle-nose pliers or a relay puller tool to gently wiggle and extract it from the socket. Avoid bending the relay pins or damaging the socket terminals.
7. 7

   Inspect relay socket
   Examine the relay socket for corrosion, damage, or burned terminals. Clean any corrosion with electrical contact cleaner if present. If terminals are melted or damaged, the relay box may need replacement or professional repair.
8. 8

   Install new cooling fan relay
   Align the new relay with the socket, ensuring the orientation matches the diagram on the relay box cover. The relay will only fit one way due to pin configuration. Press the relay firmly into the socket until it seats completely and is flush with surrounding relays.
9. 9

   Reinstall relay box cover
   Position the cover over the relay box and press down firmly until the tabs click into place on both sides. Ensure the cover is fully seated to maintain weather protection.
10. 10

    Reconnect battery negative terminal
    Place the negative battery cable back onto the battery post and tighten the 10mm nut securely. Ensure the connection is tight to prevent voltage drop or starting issues.

Reassembly

1. Ensure relay box cover is properly secured with all tabs engaged
2. Verify battery terminal is tight and corrosion-free
3. Close hood and ensure it latches properly

Verification

• Start the engine and allow it to reach operating temperature while monitoring the temperature gauge
• Turn on the air conditioning to maximum cooling, which should activate the cooling fan immediately
• Verify the cooling fan operates by listening for fan noise or visually confirming fan rotation through the grille
• Monitor engine temperature to ensure it remains in normal range and the fan cycles on and off as designed
• If equipped with dual fans, verify both fans operate correctly under load conditions
• Check for any warning lights or diagnostic trouble codes using an OBD-II scanner if available

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