This procedure covers the removal and replacement of the ignition control module (integrated igniter) on the 2019-2024 Toyota RAV4 with the 2.5L I4 gasoline engine.

Warnings

Tools required

Parts

• Ignition control module (integrated igniter) × 1 — Use OEM specification
• Engine cover clips (if broken) × 1 — Use OEM specification

Preparation

1. Ensure engine is completely cool
2. Park vehicle on level surface and engage parking brake
3. Disconnect negative battery terminal and wait 90 seconds
4. Gather all tools and replacement parts

Procedure

1. 1

   Remove engine cover
   Grasp the engine cover firmly and pull upward to release the mounting clips. The cover is held by push clips only and requires no tools. Set aside in a clean area.
2. 2

   Locate ignition control module
   On the 2.5L I4 engine, the ignition control module is typically mounted on the valve cover or integrated into the wiring harness near the ignition coils. Identify the module by tracing the main ignition coil connector harness to its control unit, usually located on the driver's side of the engine.
3. 3

   Remove air intake components if necessary
   If the ignition control module is obstructed by the air intake tube or air box, loosen the hose clamp at the throttle body and remove any mounting bolts or clips securing the intake tube. Move components aside to access the module.
4. 4

   Disconnect electrical connectors
   Press the locking tab on each electrical connector going to the ignition control module and carefully pull the connectors straight off. Note the orientation and routing of each connector for reinstallation. There may be 1-3 connectors depending on the specific module configuration.
5. 5

   Remove ignition coils if required
   If the ignition control module is beneath or integrated with the ignition coil assembly, disconnect each coil connector by pressing the locking tab and pulling off. Remove the ignition coil mounting bolt from each coil using an 8mm or 10mm socket, then pull the coils straight up with a twisting motion to release them from the spark plug wells.
   Torque spec

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

   Clean spark plug wells
   If ignition coils were removed, use compressed air or a clean lint-free cloth to remove any debris from the spark plug wells before proceeding. This prevents contamination from entering the combustion chamber.
7. 7

   Remove ignition control module mounting hardware
   Remove the bolts or brackets securing the ignition control module to the valve cover or engine. These are typically 10mm mounting bolts. Keep all hardware organized for reinstallation.
   Torque spec

   Mounting Bolts27 Nm (20 lb-ft)

   Bracket Bolts20 Nm (15 lb-ft)
8. 8

   Remove ignition control module
   Carefully lift the ignition control module away from the engine. If there is any adhesive or thermal compound, gently break the seal. Inspect the mounting surface for damage or corrosion.
9. 9

   Prepare new ignition control module
   Inspect the new module to ensure it matches the original exactly. Apply a small amount of dielectric grease to any electrical connectors on the new module if recommended by the manufacturer. Ensure all mounting holes and alignment features are clean.
10. 10

    Install new ignition control module
    Position the new ignition control module in its mounting location, ensuring proper alignment with all mounting holes and connector access. Install mounting bolts or brackets and tighten to specification.
    Torque spec

    Mounting Bolts27 Nm (20 lb-ft)

    Bracket Bolts20 Nm (15 lb-ft)
11. 11

    Reconnect electrical connectors
    Connect all electrical connectors to the ignition control module in the same orientation as removal. Ensure each connector locks firmly into place with an audible click. Verify secure connection by gently tugging on each connector.
12. 12

    Reinstall ignition coils
    If removed, apply a small amount of dielectric grease to the inside of each ignition coil boot. Press each coil firmly into its spark plug well until fully seated. Install the coil mounting bolts and torque to specification. Reconnect all coil electrical connectors.
    Torque spec

    Ignition Coil Bolts8 Nm (6 lb-ft)
13. 13

    Reinstall air intake components
    If air intake components were removed, reinstall them in reverse order of removal. Ensure all hose clamps are secure and all mounting bolts are properly tightened.
14. 14

    Reinstall engine cover
    Align the engine cover with its mounting clips and press down firmly until all clips engage with an audible click.

Reassembly

1. Reconnect the negative battery terminal and tighten securely
2. Ensure all electrical connectors are fully seated and locked
3. Verify no tools or parts are left in the engine compartment

Verification

• Turn ignition to ON position (do not start) and verify no warning lights related to ignition system appear
• Start the engine and listen for smooth operation with no misfires or rough idle
• Allow engine to reach operating temperature and verify stable idle and normal operation
• Use an OBD-II scanner to check for any diagnostic trouble codes related to ignition system
• Test drive the vehicle and confirm normal acceleration and performance with no hesitation or misfires

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