This procedure covers removal and replacement of the engine bay fuse box assembly on a 2019-2024 Toyota RAV4 with the 2.5L I4 gas engine.

Warnings

Tools required

Parts

• Engine bay fuse box assembly × 1 — Use OEM specification
• Fuse box cover × 1 — If damaged during removal
• Wire harness retaining clips × 1 — Replace any broken clips

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn ignition off and remove key from vehicle
3. Open hood and secure with prop rod
4. Photograph fuse box cover diagram and all visible wiring connections
5. Document radio security code if applicable before battery disconnect

Procedure

1. 1

   Disconnect battery
   Locate the battery in the engine bay. Using a 10mm socket, loosen the negative terminal bolt first, then remove the cable and secure it away from the battery post. Repeat for the positive terminal. Wait a minimum of 90 seconds before proceeding.
   Torque spec

   Battery Terminal Bolts6 Nm (4 lb-ft)
2. 2

   Remove fuse box cover
   Release the clips securing the fuse box cover by pressing the tabs on each side. Lift the cover off and set aside. Remove the fuse diagram card if present and keep for reference.
3. 3

   Remove battery hold-down and tray if needed
   If the fuse box is mounted behind or adjacent to the battery, remove the battery hold-down bracket using a 10mm socket. Disconnect any battery vent tubes. Remove the battery from the tray and set aside safely. Remove the battery tray mounting bolts if access requires it.
   ⚠Battery weighs approximately 40 lbs. Use proper lifting technique
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
4. 4

   Document and remove electrical connections
   Photograph each large harness connector on the fuse box assembly before removal. Release connector locks by pressing release tabs and carefully wiggle connectors free. Label each connector position with tape if multiple similar connectors are present. Note that some connectors have secondary locks that must be released first.
5. 5

   Disconnect ground straps
   Locate ground strap(s) connected to the fuse box mounting bracket or nearby chassis. Using a 10mm or 12mm socket, remove ground strap bolts. Note exact mounting location as proper grounding is critical for electrical system operation.
   Torque spec

   Ground Bolt14 Nm (10 lb-ft)

   Ground Strap Bolts12 Nm (9 lb-ft)
6. 6

   Remove internal terminals and power cables
   Identify large battery feed cables and other internal terminal connections at the fuse box. These typically use 10mm or 12mm nuts. Remove the terminal nuts and carefully lift cables free. Keep track of cable routing and stacking order as they must be reinstalled in the same configuration.
   ⚠Even with battery disconnected, capacitors in some circuits may retain charge. Avoid touching exposed terminals
   Torque spec

   Battery Terminal Bolts6 Nm (4 lb-ft)
7. 7

   Release wire harness clips and routing
   Trace all harnesses connected to the fuse box and release any clips, ties, or brackets securing them to the vehicle. You may need to detach several harness routing clips along the fender and inner fender area to gain enough slack for fuse box removal. Do not force harnesses; find and release all retention points.
8. 8

   Remove fuse box mounting bolts
   Locate the fuse box mounting bolts, typically 3-4 bolts securing the assembly to the fender or inner fender panel. Using a 10mm or 12mm socket with extension, remove all mounting bolts. Support the fuse box as you remove the final bolt.
   ⚠Fuse box assembly is heavier than it appears due to internal relays and bussing. Support weight during removal
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
9. 9

   Remove fuse box assembly
   Carefully maneuver the fuse box assembly out of the engine bay. You may need to rotate or angle it to clear surrounding components. Check for any remaining harness connections or clips before fully removing. Place the old fuse box on a clean work surface.
10. 10

    Transfer components to new fuse box
    If installing a new or remanufactured fuse box, transfer all fuses and relays from the old unit to the new unit in their exact positions using your photos as reference. Check that all fuses are properly seated. If the new box does not include internal modules, transfer those as well.
    Torque spec

    Module Mounting Bolts8 Nm (6 lb-ft)
11. 11

    Install new fuse box assembly
    Position the new fuse box assembly into the mounting location, carefully routing connected harnesses. Align mounting holes with the fender or inner panel. Install mounting bolts finger-tight initially. Verify proper fitment and alignment before final tightening to specified torque.
    Torque spec

    Module Mounting Bolts8 Nm (6 lb-ft)
12. 12

    Reconnect power cables and internal terminals
    Install power feed cables and other terminal connections to the fuse box in the exact order and configuration documented during removal. Clean any corrosion from terminal surfaces with electrical contact cleaner. Torque terminal nuts to specification. Apply dielectric grease to exposed terminals if desired.
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)
13. 13

    Reconnect ground straps
    Reinstall ground strap(s) to their original mounting locations. Ensure mating surfaces are clean and free of paint or corrosion for proper electrical contact. Install bolts and torque to specification.
    Torque spec

    Ground Bolt14 Nm (10 lb-ft)

    Ground Strap Bolts12 Nm (9 lb-ft)
14. 14

    Reconnect electrical harness connectors
    Connect all large harness connectors to the fuse box, referencing your photos to ensure correct positions. Push connectors fully into place until locking tabs click. Verify each connector is fully seated and locked. Reinstall any secondary locks if present.
15. 15

    Secure harness routing and reinstall battery
    Reinstall all wire harness clips and routing brackets. Ensure harnesses follow original paths and have no sharp bends or contact with hot or moving components. If removed, reinstall battery tray and hold-down bracket. Reinstall battery. Reconnect positive terminal first, then negative terminal. Torque battery terminal bolts to specification.
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)

    Module Mounting Bolts8 Nm (6 lb-ft)
16. 16

    Install fuse box cover and verify
    Reinstall the fuse box cover, ensuring all clips engage properly. If cover has mounting screws, torque to specification. Double-check that no tools or parts remain in the engine bay.
    Torque spec

    Cover Screws11 Nm (8 lb-ft)

Reassembly

1. Ensure all electrical connectors are fully seated with locking tabs engaged
2. Verify all ground connections are tight and making clean metal-to-metal contact
3. Confirm battery terminals are clean, tight, and torqued to specification
4. Reinstall any air intake components, battery covers, or engine covers removed for access

Verification

• Turn ignition to ON position (do not start). Verify instrument cluster illuminates with no unusual warning lights
• Check that all interior and exterior lights function correctly
• Start engine and verify normal operation with no warning lights
• Test all major electrical systems: HVAC blower, power windows, radio, wipers, headlights, and horn
• Initialize power window auto-up/down feature by fully lowering then fully raising each window and holding switch for 2 seconds
• Check for any blown fuses or improperly seated relays if any systems are non-functional
• Use scan tool to check for diagnostic trouble codes if warning lights are present
• Reset clock and radio presets as needed

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