This procedure covers the replacement of the main relay (EFI relay) in the engine compartment fuse box on a 2019-2024 Toyota RAV4 with the 2.5L I4 engine.

Warnings

Tools required

Parts

• Main relay (EFI relay) × 1 — 90987-02022 or equivalent

Preparation

1. Ensure the engine is off and the ignition key is removed from the vehicle
2. Open the hood and locate the engine compartment fuse/relay box on the driver's side near the battery
3. Have your replacement relay available and verify it matches the existing relay configuration
4. Ensure you have adequate lighting to see inside the fuse box

Procedure

1. 1

   Disconnect the battery negative terminal
   Using a 10mm socket, loosen the negative (-) battery terminal bolt. Remove the cable from the battery post and secure it away from the terminal to prevent accidental contact. Do not overtighten when reconnecting.
   Torque spec

   Battery Terminal Bolts6 Nm (4 lb-ft)
2. 2

   Wait for system discharge
   Wait at least 90 seconds to allow all electrical systems to fully discharge and capacitors to drain. This is critical for safety when working with electronic components.
   ⚠Do not skip this waiting period as residual power can cause component damage or personal injury.
3. 3

   Open the engine compartment fuse box
   Locate the black fuse/relay box on the driver's side of the engine compartment near the battery. Release the retaining clips on both sides of the cover by pressing or pulling them outward, then lift the cover straight up to remove it. Set the cover aside in a clean location.
   ℹ️The cover has a diagram showing relay and fuse positions. Take a photo for reference if needed.
4. 4

   Locate the main relay
   Identify the main relay (also called EFI relay) in the fuse box. It is typically a larger relay located in the upper section of the box. Consult the diagram on the underside of the fuse box cover or your vehicle's owner's manual to confirm the exact location. The relay position is usually labeled 'EFI MAIN' or 'EFI NO.2'.
5. 5

   Remove the old main relay
   Firmly grasp the main relay with your fingers on opposite sides. Pull straight upward with steady, even pressure to extract the relay from its socket. The relay has multiple pins that must be pulled completely clear of the socket. If it is difficult to remove, gently rock it side to side while pulling upward.
   ⚠Do not bend or twist the relay excessively as this can damage the socket pins.
6. 6

   Inspect the relay socket
   Examine the relay socket for any corrosion, debris, or damaged pins. If corrosion is present, clean the socket contacts carefully with electrical contact cleaner. Check that all socket pins are straight and undamaged. If damage is found, the entire fuse box may require replacement.
7. 7

   Install the new main relay
   Align the new relay with the socket, ensuring the pin configuration matches the socket layout. The relay will only fit in one orientation. Press the relay firmly and evenly into the socket until it is fully seated and flush with the surrounding relays. Ensure all pins are properly inserted.
   ⚠Do not force the relay if it does not seat easily. Verify pin alignment and orientation before applying pressure.
8. 8

   Reinstall the fuse box cover
   Position the fuse box cover over the box, aligning the tabs and clips. Press down firmly until you hear or feel the retaining clips engage on both sides. Verify the cover is secure and properly seated.
9. 9

   Reconnect the battery
   Place the negative battery cable back onto the negative battery post. Using a 10mm socket, tighten the terminal bolt to the specified torque. Ensure the connection is secure but do not exceed the torque specification to avoid damaging the terminal.
   Torque spec

   Battery Terminal Bolts6 Nm (4 lb-ft)

Reassembly

1. Ensure the fuse box cover is properly secured with all clips engaged
2. Verify the battery terminal is tight and has good contact

Verification

• Turn the ignition key to the ON position (without starting the engine) and verify that the dashboard lights illuminate normally
• Start the engine and confirm it starts normally without hesitation or unusual behavior
• Check that all electrical systems function properly, including fuel pump priming sound when ignition is turned on
• Verify no warning lights remain illuminated on the dashboard after startup
• If the check engine light is on or the vehicle does not start, recheck the relay installation and ensure it is fully seated

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