This procedure covers the replacement of the horn relay located in the engine compartment fuse/relay box on the 2019-2024 Toyota RAV4 with 2.5L I4 engine.

Warnings

Tools required

Parts

• Horn relay × 1 — Toyota 90987-02028 or equivalent 12V automotive relay

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 if recently operated
4. Open hood and secure with prop rod

Procedure

1. 1

   Locate the engine compartment fuse/relay box
   The fuse/relay box is located on the driver's side of the engine compartment, near the battery. It is a black rectangular box with a removable cover.
2. 2

   Remove the fuse box cover
   Release the clips securing the fuse box cover by pressing or pulling the tabs on each side. Lift the cover straight up and off the box. The relay diagram is typically printed on the underside of the cover.
3. 3

   Identify the horn relay
   Using the relay diagram on the fuse box cover, locate the horn relay position. The horn relay is typically labeled 'HORN' and is a cube-shaped relay with 4 or 5 pins. It is usually positioned in the front section of the relay box.
4. 4

   Remove the failed horn relay
   Grip the horn relay firmly and pull straight up with steady pressure to remove it from its socket. If the relay is difficult to remove, gently rock it side-to-side while pulling upward, or use needle-nose pliers to carefully extract it. Avoid bending the relay pins or damaging the socket.
5. 5

   Inspect the relay socket
   Examine the relay socket for any signs of corrosion, melting, or damage to the terminals. Clean any corrosion with electrical contact cleaner if present. If the socket shows signs of heat damage or melted plastic, the fuse box may need further diagnosis.
6. 6

   Install the new horn relay
   Align the new horn relay with the socket, ensuring the pins match the terminal configuration. The relay will only fit one way. Press the relay firmly into the socket until it is fully seated and sits flush with the other relays.
7. 7

   Reinstall the fuse box cover
   Position the fuse box cover over the relay box, aligning the clips. Press down firmly until all clips engage and the cover is secure.

Reassembly

1. Ensure fuse box cover is properly secured with all clips fully engaged
2. Verify no tools or parts are left in the engine compartment
3. Close hood securely

Verification

• Turn ignition to ON position (engine does not need to run)
• Press the horn button on the steering wheel and verify the horn sounds properly
• Test horn function multiple times with both short and sustained presses
• If horn still does not work, verify horn fuse is intact and check horn circuit wiring and horn assembly itself

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