This procedure covers the removal and replacement of spark plugs on the 2019-2024 Toyota RAV4 2.5L I4 gasoline engine, including ignition coil removal and proper gapping.

Warnings

Tools required

Parts

• Spark plugs × 4 — Toyota 90919-01275 or NGK 95770 (iridium)

Preparation

1. Park vehicle on level surface and engage parking brake
2. Allow engine to cool completely (at least 1 hour after running)
3. Open hood and prop securely
4. Verify you have the correct spark plugs for your specific model year
5. Check gap specification on new spark plugs (typically 0.039-0.043 inches for this engine)

Procedure

1. 1

   Remove engine cover
   Grasp the plastic engine cover firmly and pull upward to release the clips. The cover is held by push-clips only and does not require tools to remove. Set aside in a clean area.
   Torque spec

   Engine Cover Clips3 Nm (2 lb-ft)
2. 2

   Access ignition coils
   Locate the four ignition coils on top of the engine. They are black cylindrical components with electrical connectors on top. The coils are positioned directly above each spark plug.
3. 3

   Disconnect ignition coil connectors
   Press the release tab on each ignition coil electrical connector and pull straight up to disconnect. Do this for all four coils. Note the connector positions if they differ.
4. 4

   Remove ignition coil mounting bolts
   Using a 10mm socket, remove the single bolt securing each ignition coil. Keep bolts organized as they will be reused. Each coil has one bolt located on the side or top of the coil.
   Torque spec

   Ignition Coil Bolt11 Nm (8 lb-ft)
5. 5

   Extract ignition coils
   Grasp each ignition coil firmly and pull straight up with a twisting motion to remove from the spark plug well. The coil boot may stick slightly. Inspect the rubber boot on each coil for tears or damage and replace if necessary.
6. 6

   Clean spark plug wells
   Use compressed air or a shop vacuum to remove any dirt, debris, or oil from around the spark plug wells before removing plugs. This prevents contamination from entering the cylinder. Inspect wells for oil accumulation which may indicate valve cover gasket leakage.
   ⚠Ensure no debris falls into the cylinder when spark plugs are removed. Even small particles can cause significant engine damage.
7. 7

   Remove old spark plugs
   Using a spark plug socket with extension, carefully loosen each spark plug by turning counterclockwise. Once loose, unthread by hand to prevent cross-threading. Remove all four plugs and inspect electrodes and insulators for wear, fouling, or damage.
8. 8

   Gap new spark plugs
   Using a spark plug gap tool, verify each new spark plug is gapped to specification (typically 0.039-0.043 inches for this engine - verify with plug manufacturer or service manual). Adjust if necessary by carefully bending the ground electrode. Do not gap iridium plugs unless absolutely necessary as electrodes are fragile.
   ℹ️Most modern iridium plugs come pre-gapped from the factory. Verify gap but avoid unnecessary adjustment.
9. 9

   Prepare and install new spark plugs
   Apply a small amount of anti-seize compound to the threads of each new spark plug if desired (avoid getting any on electrodes). Thread each plug by hand into the cylinder head, turning clockwise. Ensure plugs thread smoothly without resistance. If resistance is felt, remove and restart to avoid cross-threading.
   ⚠Cross-threading spark plugs can destroy cylinder head threads requiring expensive repair. Always start threading by hand.
10. 10

    Torque spark plugs to specification
    Using a torque wrench and spark plug socket, tighten each spark plug to 20.0 Nm (15.0 lb-ft). Torque in a criss-cross pattern (cylinders 1-4-2-3 if possible) for even sealing.
    Torque spec

    Spark Plug20 Nm (15 lb-ft)
11. 11

    Reinstall ignition coils
    Apply a thin layer of dielectric grease to the inside of each ignition coil boot if desired. Push each coil firmly into its spark plug well, ensuring it seats fully onto the spark plug terminal. You should feel it click into place.
12. 12

    Install ignition coil bolts
    Insert and hand-tighten the mounting bolt for each ignition coil. Using a torque wrench with 10mm socket, tighten each bolt to 11.0 Nm (8.0 lb-ft). Do not overtighten as this can crack the coil housing.
    Torque spec

    Ignition Coil Bolt11 Nm (8 lb-ft)
13. 13

    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 fully seated and locked.
14. 14

    Reinstall engine cover
    Align the engine cover with the mounting clips and press down firmly at each clip location until all clips snap into place. Ensure cover is fully seated and secure.
    Torque spec

    Engine Cover Clips3 Nm (2 lb-ft)

Reassembly

1. Double-check all electrical connectors are fully seated and locked
2. Verify engine cover is properly installed and all clips are engaged
3. Ensure no tools or parts are left in the engine compartment

Verification

• Start the engine and verify it runs smoothly without misfires or rough idle
• Check that the check engine light does not illuminate
• Listen for any unusual noises that might indicate improper coil seating
• Perform a short test drive to confirm normal engine operation and acceleration
• If using a scan tool, verify no misfire codes are present after test drive

More procedures for this vehicle