This procedure covers the removal and replacement of the electric power steering motor on a 2019-2024 Toyota RAV4 with the 2.5L I4 gas engine and FWD configuration.

Warnings

Tools required

Parts

• Electric power steering motor assembly × 1 — Use OEM specification
• Cotter pin (tie rod end) × 2 — Use OEM specification
• O-rings for power steering connections × 2 — Use OEM specification

Preparation

1. Park vehicle on level ground and set parking brake
2. Turn steering wheel to center position and verify wheels are straight
3. Disconnect negative battery terminal and wait 90 seconds minimum
4. Raise front of vehicle and support on jack stands at manufacturer-specified lift points
5. Remove both front wheels
6. Lock steering wheel in center position using a steering wheel lock bar or securely clamp to prevent rotation

Procedure

1. 1

   Remove front splash shields and covers
   Remove the front engine under cover and any splash shields blocking access to the steering rack area. These are typically held by plastic clips and bolts. Remove both front fender liners partially if needed for access to steering components.
2. 2

   Disconnect tie rod ends
   Remove the cotter pins from both tie rod end castle nuts using needle nose pliers. Loosen but do not remove the tie rod end castle nuts. Use a tie rod separator tool to break the taper between the tie rod end and steering knuckle. Once separated, remove the castle nuts completely and set aside the tie rod ends. Mark or note the orientation for reassembly.
   ⚠Do not strike the tie rod end threads with a hammer - this will damage the threads and require replacement
   Torque spec

   Tie Rod End Castle Nut55 Nm (41 lb-ft)
3. 3

   Disconnect steering column intermediate shaft
   Locate the steering column intermediate shaft connection at the steering rack input shaft. Remove the pinch bolt (typically 14mm) securing the intermediate shaft to the steering rack. Carefully separate the intermediate shaft from the rack input shaft. Mark the orientation of the shaft for proper reassembly alignment.
   ⚠Ensure steering wheel remains locked in center position - any rotation can damage the clock spring
4. 4

   Disconnect electrical connectors
   Locate the electrical connectors on the EPS motor assembly. Depress the locking tabs and carefully disconnect all electrical connectors from the power steering motor. Note the routing of wiring harnesses for reassembly. Secure connectors away from work area to prevent damage.
5. 5

   Remove steering rack mounting bolts
   Locate the steering rack mounting bolts that secure the rack assembly to the crossmember. There are typically two main mounting bolts. Support the steering rack with one hand or use a transmission jack. Remove the steering rack mounting bolts completely.
   ⚠The steering rack assembly is heavy - ensure it is properly supported before removing mounting bolts
   Torque spec

   Rack Bolts102 Nm (75 lb-ft)
6. 6

   Remove EPS motor mounting bolts
   Locate the mounting bolts securing the electric power steering motor to the steering rack housing. These are typically located on the motor housing itself. Remove all mounting bolts securing the EPS motor assembly to the rack.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
7. 7

   Remove EPS motor assembly
   Carefully separate the EPS motor assembly from the steering rack housing. The motor may require gentle prying or wiggling to break any seal or gasket bond. Be careful not to damage the mating surfaces on the rack housing. Remove the motor completely from the vehicle.
   ⚠Inspect the mating surface on the rack for damage - any scoring or damage may require rack replacement
8. 8

   Prepare new EPS motor
   Clean the mating surface on the steering rack housing using a wire brush or non-abrasive cleaner. Inspect for any damage or debris. Compare the new EPS motor to the old unit to verify correct replacement part. Install new O-rings on the motor housing if equipped, lightly lubricating with clean ATF or assembly lube.
9. 9

   Install new EPS motor
   Position the new EPS motor assembly onto the steering rack housing, ensuring proper alignment of the motor shaft with the rack mechanism. Align all mounting holes. Install the EPS motor mounting bolts and tighten in a cross-pattern to ensure even seating.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)
10. 10

    Reinstall steering rack
    Position the steering rack assembly back into the mounting location on the crossmember. Align the mounting holes and install the steering rack mounting bolts. Tighten the rack mounting bolts to specification in the proper sequence.
    Torque spec

    Rack Bolts102 Nm (75 lb-ft)
11. 11

    Reconnect intermediate shaft and electrical
    Align the steering column intermediate shaft with the rack input shaft, matching the marks made during disassembly. Install the pinch bolt and tighten securely. Reconnect all electrical connectors to the EPS motor, ensuring they click into place and locks engage. Verify proper routing of wiring harnesses away from moving components and heat sources.
12. 12

    Reconnect tie rod ends
    Install both tie rod ends back onto the steering knuckles, ensuring the taper seats properly. Install the castle nuts and tighten to specification. Align the castle nut slots with the tie rod end holes and install new cotter pins. Bend cotter pins to secure.
    ℹ️If castle nut slots do not align with cotter pin hole, tighten slightly more until alignment - never loosen to align
    Torque spec

    Tie Rod End Castle Nut55 Nm (41 lb-ft)
13. 13

    Reinstall covers and wheels
    Reinstall all splash shields, under covers, and fender liners removed during disassembly. Ensure all clips and fasteners are properly seated. Reinstall both front wheels and hand-tighten lug nuts in a star pattern.
14. 14

    Lower vehicle and final torque
    Lower the vehicle to the ground. Remove the steering wheel lock. Torque the wheel lug nuts to specification in a star pattern with the vehicle weight on the wheels.
    Torque spec

    Wheel Lug Nuts136 Nm (100 lb-ft)
15. 15

    Reconnect battery and initialize system
    Reconnect the negative battery terminal. Turn the ignition to ON position without starting the engine. Turn the steering wheel fully left and right several times to allow the EPS system to initialize and calibrate. Start the engine and verify no warning lights illuminate. Test steering operation at idle.
    ℹ️Some vehicles may require a steering angle sensor calibration using a scan tool after steering component replacement

Reassembly

1. Torque all fasteners to specification using a calibrated torque wrench
2. Replace all single-use fasteners including cotter pins and O-rings
3. Verify steering wheel remains centered after reassembly
4. Double-check all electrical connectors are fully seated and locked

Verification

• Start engine and verify no EPS warning lights are illuminated on instrument cluster
• Turn steering wheel lock to lock while stationary - should be smooth with no binding or unusual noises
• Test drive vehicle at low speed in a safe area - verify steering feels normal with proper assist
• Check for any fluid leaks around work area (although this is electric power steering with no hydraulic fluid)
• Verify steering wheel returns to center properly after turns
• Schedule a professional wheel alignment as steering components were disconnected

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