This procedure covers the removal and replacement of all four ignition coils on the 2019-2024 Toyota RAV4 with the 2.5L I4 gasoline engine, including access to spark plugs if replacement is needed.

Warnings

Tools required

Parts

• Ignition coil × 4 — 90919-02265 or equivalent
• Spark plug × 4 — Use OEM specification (optional)

Preparation

1. Ensure engine is completely cool to the touch
2. Disconnect negative battery terminal and wait 90 seconds for airbag system to discharge
3. Remove engine cover by pulling upward on four corner clips - no tools required
4. Locate all four ignition coils positioned directly on top of the valve cover

Procedure

1. 1

   Disconnect electrical connectors
   Press the locking tab on each ignition coil electrical connector and pull straight up to disconnect. There are four connectors total, one per coil. Mark or photograph connector positions if needed for reassembly reference.
2. 2

   Remove ignition coil mounting bolts
   Using a 10mm socket, remove the single bolt securing each ignition coil to the valve cover. Keep bolts organized as they will be reused. Each coil has one bolt located at the top of the coil body.
3. 3

   Extract ignition coils
   Grasp each ignition coil firmly and pull straight upward with a slight twisting motion to break the rubber boot seal. The coil will slide out of the spark plug well. Expect some resistance from the rubber seal. Do not pry or bend the coils during removal.
   ⚠If coils are difficult to remove, gently twist back and forth while pulling. Do not use excessive force as this may damage the coil boot or spark plug.
4. 4

   Clean spark plug wells
   Use compressed air or a vacuum to remove any debris, dirt, or oil from the spark plug wells. Ensure wells are completely clean before proceeding. Any debris left in the wells can fall into the combustion chamber during spark plug service.
   ⚠If oil is present in spark plug wells, valve cover gaskets or plug tube seals may be leaking and should be addressed separately.
5. 5

   Remove spark plugs (if replacing)
   If replacing spark plugs, use a spark plug socket with extension to remove each plug by turning counterclockwise. Remove plugs carefully to avoid dropping debris into cylinders. Inspect old plugs for wear patterns or damage.
6. 6

   Install new spark plugs (if applicable)
   Apply a small amount of anti-seize compound to the threads of new spark plugs (avoid getting compound on electrodes). Thread plugs by hand to prevent cross-threading, then tighten to specification using torque wrench. Install all four plugs before proceeding to coil installation.
   Torque spec

   Spark Plugs - Aluminum Head20 Nm (15 lb-ft)
7. 7

   Prepare new ignition coils
   Inspect new ignition coils for any shipping damage. Apply a thin layer of dielectric grease to the inside of each coil boot (the rubber end that contacts the spark plug). This aids in future removal and prevents moisture intrusion.
8. 8

   Install ignition coils
   Align each ignition coil with its spark plug well and push down firmly until the coil boot seats completely on the spark plug terminal. You should feel the coil bottom out and sit flush against the valve cover. Ensure proper seating before installing bolts.
   ⚠Coils must be fully seated before tightening bolts. A partially seated coil will cause misfires and may damage the coil or spark plug.
9. 9

   Secure ignition coil bolts
   Install the mounting bolt for each ignition coil and tighten to specification using a torque wrench. Tighten bolts in a cross pattern (cylinders 1, 4, 2, 3 if possible) to ensure even seating. Do not overtighten as valve cover is aluminum.
   Torque spec

   Ignition Coil Bolts8 Nm (6 lb-ft)
10. 10

    Reconnect electrical connectors
    Push each electrical connector onto its corresponding ignition coil until you hear and feel a positive click. Gently tug on each connector to verify it is securely locked in place. Ensure no pins are bent and connectors are fully seated.
11. 11

    Reinstall engine cover
    Align engine cover with the four mounting clips on the engine. Press down firmly at each corner until all clips snap into place. Ensure cover is seated evenly and securely.
12. 12

    Reconnect battery
    Reconnect the negative battery terminal and tighten securely. This completes the installation. Vehicle is ready for verification testing.

Reassembly

1. Ensure all four ignition coil electrical connectors are securely locked with audible clicks
2. Verify engine cover is properly seated on all four mounting clips
3. Double-check that no tools or parts were left in the engine bay

Verification

• Start the engine and allow it to idle. Engine should start immediately and run smoothly without hesitation
• Listen for any misfires, rough idle, or unusual sounds. Engine should idle smoothly around 600-700 RPM
• Check for diagnostic trouble codes using an OBD-II scanner. No misfire codes (P0300-P0304) should be present
• Test drive vehicle and verify smooth acceleration under light and moderate throttle with no hesitation or stumbling
• If check engine light illuminates or misfires occur, verify all coil connectors are fully seated and coils are pushed down completely onto spark plugs

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