This procedure covers the removal and replacement of a single ignition coil on the 2019-2024 Toyota RAV4 with 2.5L I4 engine, including access to the coil and verification of proper operation.

Warnings

Tools required

Parts

• Ignition coil × 1 — 90919-02260 or equivalent
• Spark plug (if replacing) × 1 — Use OEM specification

Preparation

1. Park vehicle on level ground and engage parking brake
2. Turn ignition off and remove key
3. Allow engine to cool if recently operated
4. Open hood and secure with prop rod
5. Disconnect negative battery terminal using 10mm socket and isolate cable away from terminal

Procedure

1. 1

   Remove engine cover
   Grasp the engine cover firmly and pull upward to release the snap-fit fasteners. The cover is held by rubber grommets and does not require tools. Set the cover aside in a clean area.
2. 2

   Identify target ignition coil
   Locate the ignition coil for the cylinder you are servicing. The 2.5L I4 has four coils mounted directly on top of the valve cover. Cylinders are numbered 1-4 from the timing belt end (passenger side) to the transmission end (driver side).
3. 3

   Disconnect coil electrical connector
   Press down on the tab of the electrical connector attached to the ignition coil and pull the connector straight up and away from the coil. Do not pull on the wires themselves. Wiggle gently if the connector is stuck.
4. 4

   Remove ignition coil bolt
   Using a 10mm socket with extension, remove the single bolt securing the ignition coil to the valve cover. Keep the bolt in a safe location for reinstallation.
   Torque spec

   Ignition Coil Bolts8 Nm (6 lb-ft)
5. 5

   Extract ignition coil
   Grasp the ignition coil body firmly and pull straight up with a twisting motion to break the seal between the coil boot and spark plug. If the coil is stuck, use needle-nose pliers or a coil boot puller to assist. Avoid excessive force that could damage the spark plug ceramic insulator.
   ⚠Do not pull on the electrical connector portion of the coil during removal
6. 6

   Inspect spark plug well
   Use compressed air or a shop vacuum to clean any debris, dirt, or oil from around the spark plug well before proceeding. Inspect for oil pooling in the well, which may indicate a valve cover gasket leak requiring separate attention.
7. 7

   Inspect or replace spark plug (optional)
   If replacing the spark plug, remove it using a 16mm spark plug socket with extension. Inspect the old plug for wear, fouling, or damage. Apply anti-seize compound to the threads of the new spark plug (avoid getting any on the electrode). Install and torque the new spark plug to specification.
   Torque spec

   Spark Plugs - Aluminum Head20 Nm (15 lb-ft)
8. 8

   Prepare new ignition coil
   Inspect the new ignition coil boot for damage and ensure it is clean. Apply a thin layer of dielectric grease inside the coil boot to prevent moisture intrusion and aid future removal. Inspect the coil spring terminal for corrosion or damage.
9. 9

   Install new ignition coil
   Align the ignition coil with the spark plug and press down firmly until the coil boot is fully seated on the spark plug. The coil should sit flush against the valve cover mounting surface. Ensure the bolt hole in the coil aligns with the threaded hole in the valve cover.
10. 10

    Install and torque coil bolt
    Thread the ignition coil bolt by hand to ensure proper alignment, then torque to specification using a torque wrench. Do not overtighten as this can crack the coil housing.
    Torque spec

    Ignition Coil Bolts8 Nm (6 lb-ft)
11. 11

    Reconnect electrical connector
    Push the electrical connector onto the ignition coil until you hear and feel a distinct click, confirming it is fully seated. Gently tug on the connector to verify it is locked in place.
12. 12

    Reinstall engine cover
    Align the engine cover grommets with the posts on the engine and press down firmly until all grommets snap into place. Ensure the cover is secure and properly seated.
13. 13

    Reconnect battery and clear codes
    Reconnect the negative battery terminal and torque to specification. If the coil replacement was performed due to a misfire code, clear diagnostic trouble codes using an OBD-II scanner or by driving through a complete drive cycle.

Reassembly

1. Ensure all electrical connectors are fully seated and locked
2. Verify engine cover is properly installed and secure
3. Check that no tools or parts were left in the engine bay

Verification

• Start the engine and listen for smooth idle with no misfires or rough running
• Verify the check engine light does not illuminate after starting
• Allow engine to reach operating temperature and confirm continued smooth operation
• If available, use an OBD-II scanner to verify no misfire codes are present
• Test drive the vehicle to confirm normal acceleration and no hesitation under load

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