This procedure covers removal and replacement of the interior fuse box assembly located on the driver's side lower dash panel of the 2019-2024 Toyota RAV4 with 2.5L I4 engine.

Warnings

Tools required

Parts

• Interior fuse box assembly × 1 — Use OEM specification
• Panel clips (assorted) × 5 — 90467-07212 or equivalent
• Wiring harness connector seals (if damaged) × 1 — Use OEM specification

Preparation

1. Park vehicle on level surface and engage parking brake
2. Turn ignition to OFF position and remove key/fob from vehicle
3. Open driver's door and lower driver's side window fully
4. Disconnect negative battery terminal and secure cable away from battery post
5. Wait minimum 90 seconds for airbag system capacitor discharge
6. Adjust steering column to lowest and most extended position for access

Procedure

1. 1

   Remove lower dash panel
   Locate the lower driver's side dash panel below the steering column. Remove two Phillips screws from the bottom edge of the panel. Carefully pull the panel away from the dash using panel removal tools to release the retaining clips along the top edge. Disconnect the hood release cable by pressing the retaining tab and sliding the cable end from its bracket. Remove the panel completely.
2. 2

   Remove knee bolster
   Locate the knee bolster panel directly above where the lower panel was removed. Remove four mounting bolts using a 10mm socket. Two bolts are located at the top edge and two at the bottom near the steering column support. Carefully pull the knee bolster forward and downward to disengage it from the dash structure. Set aside.
3. 3

   Access fuse box mounting area
   With the knee bolster removed, the interior fuse box will be visible on the left side of the steering column support structure. Use a flashlight to identify all electrical connectors attached to the back of the fuse box. Take clear photographs of connector positions and wire routing for reassembly reference.
4. 4

   Disconnect main harness connectors
   Beginning with the largest connector at the top of the fuse box, depress the locking tab while pulling the connector straight back from the fuse box. The RAV4 typically has three to four main harness connectors. Each connector has a different colored locking mechanism (gray, black, or green). Press the tab fully before pulling to avoid damaging connector pins. Work methodically from top to bottom.
   ⚠Connector locking tabs are fragile. Use controlled pressure only on the tab mechanism, not on the connector body.
5. 5

   Disconnect secondary circuits
   Remove smaller individual circuit connectors from the sides and bottom of the fuse box. These include dedicated circuits for specific modules and may have twist-lock or sliding lock mechanisms. Note the orientation of each connector as some are keyed but can be difficult to see during reinstallation.
6. 6

   Disconnect ground strap
   Locate the ground strap attached to the side or bottom of the fuse box mounting bracket. Remove the ground strap bolt using a 10mm socket. Note the position and orientation of the ground lug and any washers. Clean the contact surface with electrical contact cleaner if corrosion is present.
   Torque spec

   Ground Strap Bolts12 Nm (9 lb-ft)
7. 7

   Remove fuse box mounting fasteners
   Locate the three mounting bolts securing the fuse box assembly to the dash support structure. Two bolts are typically on the left side bracket and one at the top rear. Remove all three bolts using a 10mm socket. Support the fuse box with one hand while removing the final bolt to prevent it from falling.
   ℹ️The fuse box assembly weighs approximately 3-4 pounds and may shift suddenly when the last mounting bolt is removed.
   Torque spec

   Module Mounting Bolts8 Nm (6 lb-ft)
8. 8

   Remove fuse box assembly
   With all connectors and mounting bolts removed, carefully maneuver the fuse box assembly out from behind the dash structure. It may be necessary to angle the assembly slightly to clear the steering column and dash support brackets. Inspect the mounting bracket for any damage or missing hardware.
9. 9

   Transfer components to new fuse box
   If replacing the fuse box, transfer all fuses and relays from the old assembly to the new one in their exact positions. Use the fuse box diagram on the cover as reference. Check each fuse for proper amperage rating and condition. Inspect relay contacts for corrosion or burning.
10. 10

    Install new fuse box assembly
    Position the new or serviced fuse box assembly into the mounting location, angling it to clear the steering column and dash supports. Align the mounting holes with the threaded bosses on the dash structure. Install all three mounting bolts finger-tight first, then torque to specification using a torque wrench, working from top to bottom.
    Torque spec

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

    Reconnect ground strap
    Position the ground strap lug onto the mounting boss, ensuring the contact surface is clean and free of paint or corrosion. Install the ground strap bolt with any washers in their original configuration. Torque the bolt to specification ensuring good electrical contact.
    Torque spec

    Ground Strap Bolts12 Nm (9 lb-ft)
12. 12

    Reconnect electrical harnesses
    Beginning with the smaller individual circuit connectors, reconnect each harness to the fuse box in the reverse order of removal. Reference your photographs to ensure correct position and orientation. Push each connector firmly until the locking tab clicks into place. Then reconnect the main harness connectors, ensuring each locks securely. Verify each connection by gently pulling back on the connector to confirm it is seated and locked.
13. 13

    Reinstall knee bolster
    Position the knee bolster panel into the dash opening, ensuring it engages with the upper dash structure correctly. Install the four 10mm mounting bolts and tighten to the appropriate specification for module mounting applications. Ensure the panel sits flush with surrounding trim.
    Torque spec

    Module Mounting Bolts8 Nm (6 lb-ft)
14. 14

    Reinstall lower dash panel
    Reconnect the hood release cable to its bracket on the lower dash panel, ensuring the retaining tab clicks into place. Position the panel into the dash opening and press firmly to engage the upper retaining clips. Install the two Phillips screws at the bottom edge and tighten to specification.
    Torque spec

    Cover Screws11 Nm (8 lb-ft)
15. 15

    Reconnect battery and initialize systems
    Reconnect the negative battery terminal and torque the terminal bolt to specification. Turn the ignition to ON position without starting the engine. Observe the instrument cluster for any warning lights that remain illuminated beyond the normal bulb check period. Cycle the ignition off and on three times to allow control modules to initialize.
    Torque spec

    Battery Terminal Bolts6 Nm (4 lb-ft)

Reassembly

1. Verify all panel clips are properly engaged and panels are flush with surrounding trim
2. Ensure hood release cable operates smoothly with no binding
3. Check that all dashboard screws and bolts are torqued to specification
4. Confirm no tools or hardware were left in the dash cavity

Verification

• Start the engine and verify normal operation with no warning lights on the instrument cluster
• Test all interior electrical functions including lights, power windows, climate control, and infotainment system
• Check operation of all safety systems including airbag indicator (should illuminate briefly then extinguish)
• Verify turn signals, hazard lights, and horn function properly
• Test power outlet/USB ports for proper operation
• Perform a visual inspection under the dash with a flashlight to ensure all connectors are fully seated and no wires are pinched
• If any warning lights persist, use a diagnostic scan tool to check for fault codes related to electrical system communication errors

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