This procedure covers the replacement of spark plugs on the 2019-2024 Toyota RAV4 with the 2.5L I4 engine. Note: This vehicle has a 4-cylinder engine, not a V6.

Warnings

Tools required

Parts

• Spark plugs (iridium) × 4 — Toyota 90919-01253 or equivalent

Preparation

1. Ensure engine is completely cool to the touch
2. Park vehicle on level surface and engage parking brake
3. Gather all tools and new spark plugs
4. Verify spark plug gap specification (typically 0.043" / 1.1mm for this engine)

Procedure

1. 1

   Remove engine cover
   Remove the plastic engine cover by releasing the clips or removing fasteners. Some models may have push clips that pull straight up, while others use bolts. Store the cover and hardware safely.
   Torque spec

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

   Locate ignition coils
   Identify all four ignition coils mounted directly above each spark plug. They are positioned along the top of the engine with electrical connectors attached to each coil.
   ℹ️Take a photo of coil positions and wire routing for reference during reassembly.
3. 3

   Disconnect ignition coil connectors
   Press the tab on each ignition coil electrical connector and carefully pull straight up to disconnect. Do this for all four coils before removing any coils from the engine.
   ⚠Do not pull on wires; press the release tab and pull only on the connector body.
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.
   Torque spec

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

   Remove ignition coils
   Carefully pull each ignition coil straight up out of the cylinder head. The coils are sealed with rubber boots that may create suction. Twist gently while pulling if resistance is encountered. Inspect the rubber boot on each coil for damage or cracking.
   ⚠If the rubber boot remains in the spark plug well, carefully extract it with needle-nose pliers before proceeding.
6. 6

   Clean spark plug wells
   Use compressed air or a shop vacuum to remove any debris, dirt, or oil from around each spark plug well. This prevents contamination from falling into the cylinders when plugs are removed.
   ⚠Ensure spark plug wells are completely clean and dry before removing spark plugs.
7. 7

   Remove old spark plugs
   Using a spark plug socket with extension, carefully loosen and remove each spark plug by turning counterclockwise. Remove plugs one at a time to maintain organization. Inspect each plug for wear patterns, fouling, or damage.
   ℹ️Abnormal wear patterns may indicate engine issues. Document any unusual conditions.
8. 8

   Prepare new spark plugs
   Verify the gap on each new spark plug using a gap tool (should be approximately 0.043" / 1.1mm or per manufacturer specification). Apply a small amount of anti-seize compound to the threads of each spark plug, avoiding the electrode area.
   ⚠Use anti-seize sparingly; excess can contaminate the electrode or cause false torque readings.
9. 9

   Install new spark plugs
   Carefully thread each new spark plug by hand into the cylinder head, turning clockwise. Start the threads carefully to avoid cross-threading. Once hand-tight, use the torque wrench and spark plug socket to tighten to specification.
   ⚠️Do not cross-thread spark plugs. If resistance is felt immediately, back out and restart. Cross-threading can destroy the aluminum cylinder head threads.
   Torque spec

   Spark Plug20 Nm (15 lb-ft)
10. 10

    Apply dielectric grease and reinstall ignition coils
    Apply a small amount of dielectric grease to the inside of each ignition coil boot. Insert each coil back into its corresponding spark plug well, ensuring it seats fully onto the spark plug. Install and hand-tighten the mounting bolt for each coil.
    ℹ️Dielectric grease prevents moisture intrusion and makes future coil removal easier.
11. 11

    Torque ignition coil bolts
    Using a torque wrench, tighten each ignition coil mounting bolt to the specified torque in a consistent pattern across all four cylinders.
    Torque spec

    Ignition Coil Bolt11 Nm (8 lb-ft)
12. 12

    Reconnect electrical connectors
    Reconnect the electrical connector to each ignition coil, ensuring each connector clicks securely into place. Verify all connections are fully seated.
    ⚠Loose connections can cause misfires and diagnostic trouble codes.
13. 13

    Reinstall engine cover
    Position the engine cover back onto the engine, aligning all clips or mounting points. Press down firmly or install fasteners to secure the cover in place.
    Torque spec

    Engine Cover Clips3 Nm (2 lb-ft)

Reassembly

1. Ensure all electrical connectors are fully seated and secure
2. Verify engine cover is properly installed and all clips/fasteners are engaged
3. Double-check that no tools or parts have been left in the engine bay

Verification

• Start the engine and listen for smooth operation with no misfires or rough idle
• Check that the check engine light does not illuminate
• Allow engine to reach operating temperature and verify smooth acceleration
• Scan for diagnostic trouble codes if any driveability concerns are present
• Inspect for any vacuum leaks or loose connections around the ignition coils

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