This procedure replaces the fuel pump relay, which controls power to the electric fuel pump. A faulty relay can prevent the engine from starting or cause intermittent stalling.

Warnings

Tools required

Parts

• Fuel pump relay × 1 — Toyota 90987-02028 or equivalent

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn ignition to OFF position and remove key
3. Allow engine to cool if recently operated (at least 15 minutes)
4. Open hood and secure with prop rod
5. Locate the engine compartment fuse/relay box on the driver's side near the battery

Procedure

1. 1

   Disconnect negative battery cable
   Using a 10mm socket, loosen the negative (-) battery terminal clamp bolt and remove the cable from the battery post. Position the cable away from the battery to prevent accidental reconnection. Wait at least 2 minutes for electrical systems to fully discharge.
   ⚠Always disconnect negative terminal first to prevent short circuits. Do not allow the cable to touch the battery post during the procedure.
2. 2

   Access the relay box
   Locate the main engine compartment relay box on the driver's side fender near the battery. Press the tab on the front of the relay box cover and lift the cover straight up to remove it. The relay box lid typically has a diagram showing relay positions.
3. 3

   Identify the fuel pump relay
   Consult the relay diagram on the underside of the relay box cover or in the owner's manual. The fuel pump relay is typically labeled 'EFI MAIN' or 'FUEL PUMP' and is usually a larger relay. On 2019-2024 RAV4 models, it is commonly located in the upper left section of the relay box. Verify identification by checking the amperage rating (typically 25-30A) and pin configuration.
   ⚠Removing the wrong relay can cause electrical system damage. Triple-check relay identification before removal.
4. 4

   Remove the old fuel pump relay
   Firmly grasp the relay body and pull straight upward with steady pressure. The relay should release from its socket with moderate force. If stuck, gently rock the relay side-to-side while pulling upward. Inspect the relay socket for corrosion, damage, or burnt terminals.
5. 5

   Inspect relay socket and terminals
   Examine the relay socket for signs of overheating (discoloration, melted plastic), corrosion (green or white deposits), or damaged pins. If any damage is present, the relay box may need replacement or professional repair. Clean minor corrosion with electrical contact cleaner and a small brush if necessary.
   ⚠If socket shows severe burning, melting, or damage, do not install new relay. The underlying electrical problem must be diagnosed and repaired first to prevent repeat failure.
6. 6

   Install new fuel pump relay
   Verify the new relay matches the pin configuration and amperage rating of the original. Align the relay pins with the socket terminals, ensuring correct orientation (relays are keyed and will only fit one way). Push the relay firmly into the socket until it seats completely and sits flush with surrounding relays. The relay should click into place.
7. 7

   Reinstall relay box cover
   Position the relay box cover over the relay box, aligning the rear tabs first. Press down firmly on the front of the cover until it clicks into place and is fully seated.
8. 8

   Reconnect battery
   Reposition the negative battery cable onto the negative battery post. Hand-tighten the clamp bolt, then torque to specification using a 10mm socket. Ensure the connection is secure and the cable cannot rotate on the post.

Reassembly

1. Ensure relay box cover is fully secured and latched
2. Verify negative battery terminal is tight and secure
3. Close hood completely

Verification

• Turn ignition to ON position (do not start engine) and listen for fuel pump priming (2-3 second whirring sound from rear of vehicle)
• Start the engine and verify it starts normally without extended cranking
• Allow engine to idle for 1-2 minutes and confirm stable operation with no stalling
• Turn engine off and restart to verify consistent starting performance
• Check for any new warning lights on the instrument cluster
• If equipped with automatic climate control or power windows, verify proper operation and re-initialize if necessary per owner's manual

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