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

Warnings

Tools required

Parts

• Spark plugs × 4 — Toyota 90919-01253 or NGK 94701 (LZKAR6AP-11)

Preparation

1. Ensure engine is completely cool to the touch
2. Park vehicle on level surface and engage parking brake
3. Open hood and secure with prop rod
4. Gather all tools and new spark plugs
5. Verify spark plug gap on new plugs is 0.039-0.043 inches (1.0-1.1mm) per Toyota specification

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-in clips only and does not require tools for removal. Set aside in a clean area.
2. 2

   Locate ignition coils
   Identify the four ignition coils positioned directly on top of the engine. Each coil has an electrical connector on top and is secured by a single 10mm bolt. Note their position for reference during reassembly.
3. 3

   Disconnect ignition coil connectors
   Press the release tab on each electrical connector and pull straight up to disconnect. Do not pull on the wires. Work on one coil at a time to maintain organization and prevent mixing up connections.
4. 4

   Remove ignition coil bolts
   Using a 10mm socket and ratchet, remove the single bolt securing each ignition coil. Keep bolts organized as they will be reused. These bolts typically have medium thread locker from the factory.
5. 5

   Extract ignition coils
   Grasp each ignition coil firmly and pull straight up with steady pressure. A slight twisting motion may help break the seal if the coil resists removal. The coil boot seals into the spark plug well and may stick slightly. Inspect the coil boot for damage or oil contamination.
   ⚠If oil is present in spark plug wells, valve cover gaskets or spark plug tube seals require service before continuing.
6. 6

   Clean spark plug wells
   Use compressed air or a shop vacuum to remove any debris, dirt, or leaves from around the spark plug area and inside the spark plug wells. This prevents contamination from falling into the cylinders during spark plug removal.
7. 7

   Remove old spark plugs
   Using a spark plug socket with extension, carefully loosen each spark plug by turning counterclockwise. Once broken loose, unscrew by hand if possible to prevent cross-threading. Remove each plug completely and inspect the electrode and ceramic insulator for abnormal wear, fouling, or damage.
8. 8

   Prepare new spark plugs
   Verify the spark plug gap is correct (0.039-0.043 inches). Apply a very small amount of anti-seize compound to the threads only, avoiding the electrode end. Use anti-seize sparingly - a thin coat on 2-3 threads is sufficient. Excessive anti-seize can affect torque readings and contaminate the cylinder.
9. 9

   Install new spark plugs
   Carefully thread each new spark plug into the cylinder head by hand, turning clockwise. Start the threads by hand first to ensure proper alignment and prevent cross-threading. Once hand-tight, use the spark plug socket and torque wrench to tighten to specification. Work on one plug at a time.
   ⚠Cross-threading spark plugs in aluminum heads can cause expensive damage. If plug does not thread easily by hand, remove and restart.
   Torque spec

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

    Apply dielectric grease to coil boots
    Apply a small amount of dielectric grease to the inside of each ignition coil boot. This helps prevent moisture intrusion, ensures good electrical contact, and makes future coil removal easier. Do not use excessive amounts.
11. 11

    Reinstall ignition coils
    Carefully align each ignition coil with its spark plug and push down firmly until it fully seats. The coil should drop approximately 1/2 inch when it engages the spark plug terminal. Ensure the coil sits flush against the valve cover surface.
12. 12

    Install ignition coil bolts
    Thread each 10mm ignition coil bolt by hand first, then tighten with a torque wrench to specification. Apply torque in a crossing pattern if working on adjacent coils to ensure even seating.
    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 locked in place.
14. 14

    Reinstall engine cover
    Align the engine cover clips with their mounting points on the engine. Press down firmly on each clip location until the cover snaps into place. Ensure all clips are fully engaged.

Reassembly

1. Double-check all electrical connectors are fully seated and locked
2. Verify engine cover is properly secured with all clips 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
• Listen for any abnormal sounds that might indicate a loose connection
• Check for diagnostic trouble codes using an OBD-II scanner if check engine light illuminates
• Allow engine to reach operating temperature and verify smooth operation under light acceleration
• Visually inspect for any signs of arcing or spark leakage around ignition coils in darkness if issues arise

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