🔧 Fusion - Ignition Coil Replacement

Your Fusion uses coil-on-plug ignition coils—one coil sits directly on top of each spark plug. Replacing a bad coil can fix misfires, rough running, poor acceleration, and a flashing check engine light.

Difficulty Level: Beginner | Estimated Time: 0.5-1.5 hours

---

⚠️ Safety & Precautions

• ⚠️ Let the engine cool fully before you start; coils sit near hot parts.
• ⚠️ Hybrid safety: do not touch any orange high-voltage cables or connectors.
• ⚠️ Keep the key fob away from the car (at least 15+ feet) so the hybrid system can’t “wake up.”
• ⚠️ Disconnect the 12V negative battery cable before unplugging coils.

---

🔧 Required Tools

You'll need the following tools for this repair:

• 10mm socket
• 8mm socket
• 1/4" drive ratchet
• 3" 1/4" drive extension
• Inch-pound torque wrench (20-200 in-lb)
• Trim removal tool
• Small flathead screwdriver
• OBD-II scan tool
• Nitrile gloves
• Safety glasses

---

🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Ignition coil - Qty: 1-4 Replace the failed one, or all four.
• Dielectric grease - Qty: 1
• Ignition coil boot (if sold separately) - Qty: 1-4

---

📋 Before You Begin

• Park on level ground, shift to Park, and set the parking brake.
• Power the car OFF and wait 5 minutes.
• Disconnect the 12V negative battery cable: use a 10mm socket to loosen the clamp and tuck the cable aside so it can’t spring back.
• A torque wrench measures tightening force accurately.

---

🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Remove the engine cover (if equipped)

• Grip the cover and pull upward to release it from the rubber grommets.
• If it feels stuck, use a trim removal tool to gently pry at a corner.

Step 2: Locate the ignition coils

• The coils sit on top of the valve cover, one per cylinder, in a row.
• Work on one coil at a time to avoid mixing up connectors.

Step 3: Unplug the coil electrical connector

• Press the connector lock tab by hand; if it’s tight, use a small flathead screwdriver to gently lift the lock.
• Pull the connector straight off—don’t pull on the wires.

Step 4: Remove the coil hold-down bolt

• Use an 8mm socket with a 1/4" drive ratchet and 3" extension to remove the bolt.
• Set the bolt aside where it won’t fall into the engine bay.

Step 5: Remove the ignition coil

• Twist the coil gently left and right to break the seal.
• Pull straight up to remove it from the spark plug tube.
• If the rubber boot stayed stuck down in the tube, use the trim removal tool carefully to lift it out.

Step 6: Prep the new coil

• Apply a small smear of dielectric grease inside the tip of the rubber boot.
• Dielectric grease helps prevent moisture and sticking.

Step 7: Install the new coil

• Push the coil straight down until you feel it seat onto the spark plug.
• Reinstall the hold-down bolt by hand first (to avoid cross-threading).
• Tighten the bolt using an inch-pound torque wrench: Torque to 62 in-lb (7 Nm).

Step 8: Reconnect the electrical connector

• Push the connector on until it clicks/locks.
• Give it a gentle tug to confirm it’s fully seated.

Step 9: Repeat for any other coils (if replacing more than one)

• Repeat Steps 3–8 for each remaining coil you are replacing.
• Replacing one at a time prevents mix-ups.

Step 10: Reinstall the engine cover and reconnect the 12V battery

• Reinstall the engine cover by aligning the grommets and pressing down firmly by hand.
• Reconnect the 12V negative cable using a 10mm socket and snug the clamp.

---

✅ After Repair

• Start your Fusion and let it idle for 1-2 minutes; it should run smoothly.
• If the check engine light was on, use an OBD-II scan tool to clear codes, then recheck for returning misfire codes.
• Test drive 10-15 minutes with light and moderate acceleration.
• If it still misfires, the next common causes are spark plugs, a vacuum leak, or a fuel/engine control issue.

---

💰 DIY vs Shop Cost

Shop Cost: $250-$650 (parts + labor)

DIY Cost: $60-$320 (parts only)

You Save: $190-$330 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 0.7-1.2 hours.

---

🎯 Ready to get started?

HowToo makes it easy: same-day/2-day shipping on every part, plus all the tools and specialty tools you need! Check out the parts and tools sections below to add everything to your cart.