🔧 Passport - Spark Plug Replacement

On your Passport’s 3.5L V6, there are 6 spark plugs (3 in the front bank and 3 in the rear bank). The front bank is easy to reach, but the rear bank typically requires removing the upper intake manifold to access the coils and plugs safely.

Difficulty Level: Intermediate | Estimated Time: 2-4 hours

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⚠️ Safety & Precautions

• ⚠️ Work on a cold engine to avoid burns and stripped threads.
• ⚠️ Disconnect the negative battery cable before unplugging coils/sensors.
• ⚠️ Keep dirt out of the intake ports; cover openings immediately.
• ⚠️ Do not over-tighten spark plugs; aluminum heads strip easily.

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🔧 Required Tools

You'll need the following tools for this repair:

• Safety glasses
• Nitrile gloves
• 10mm socket
• 12mm socket
• 14mm socket
• 3/8" drive ratchet
• 3/8" drive torque wrench (10-80 N·m range)
• 6" extension (3/8" drive)
• 12" extension (3/8" drive)
• 3/8" universal joint adapter
• 5/8" spark plug socket (rubber insert)
• Flathead screwdriver
• Needle-nose pliers
• Trim clip remover
• Compressed air blow gun
• Shop towels
• Painter’s tape and marker
• Magnetic pickup tool

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Iridium spark plugs (OE type) - Qty: 6
• Upper intake manifold gasket set - Qty: 1
• Throttle body gasket - Qty: 1
• Dielectric grease (for coil boots) - Qty: 1

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📋 Before You Begin

• Park on level ground, shift to Park, and set the parking brake.
• Let the engine cool completely (at least 1 hour after driving).
• Disconnect the battery: use a 10mm socket to remove the negative terminal and set it aside.
• Use painter’s tape and marker to label hoses/connectors you remove. This prevents mix-ups.
• A torque wrench sets bolt tightness accurately.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Remove the engine cover

• Pull up on the plastic engine cover to release it from the rubber grommets (use both hands).
• Set it aside.

Step 2: Remove the air intake duct

• Use a flathead screwdriver to loosen the hose clamps at the air box and throttle body.
• Unclip/remove any attached breather hose(s) using needle-nose pliers.
• Lift out the intake duct and set it aside.

Step 3: Replace the front bank spark plugs (front 3 cylinders)

• Unplug each ignition coil connector by pressing the tab (use a trim clip remover gently if needed).
• Remove each coil hold-down bolt using a 10mm socket.
• Twist the coil boot slightly, then pull the coil straight out.
• Blow out debris around each plug well using compressed air blow gun.
• Remove the spark plug using a 5/8" spark plug socket, 6" extension, and 3/8" ratchet.
• Install the new plug by hand first using the spark plug socket and extension (no ratchet) to prevent cross-threading.
• Tighten with a torque wrench: Torque to 18 N·m (13 ft-lbs).
• Add a small amount of dielectric grease inside the coil boot, then reinstall the coil.
• Reinstall coil bolt: Torque to 12 N·m (9 ft-lbs).

Step 4: Remove the throttle body from the intake (for rear bank access)

• Unplug the throttle body electrical connector (press the tab and pull straight back).
• Remove the throttle body mounting fasteners using a 10mm socket.
• Carefully pull the throttle body forward and set it aside with shop towels under it.
• Remove and discard the old throttle body gasket.
• Don’t pry on the throttle plate.

Step 5: Remove the upper intake manifold (rear bank access)

• Label and disconnect vacuum/EVAP hoses using needle-nose pliers as needed.
• Disconnect any remaining connectors attached to the upper intake (use a trim clip remover gently on stubborn clips).
• Remove the upper intake manifold bolts using a 12mm socket with a 3/8" ratchet and extensions.
• Lift the upper intake manifold straight up and off.
• Immediately cover the exposed intake ports with clean shop towels.
• Remove and discard the old upper intake manifold gaskets.

Step 6: Replace the rear bank spark plugs (rear 3 cylinders)

• Remove coil connectors and coil bolts using a 10mm socket.
• Pull coils out, then blow out each plug well using compressed air blow gun.
• Remove each spark plug using a 5/8" spark plug socket, 12" extension, and 3/8" universal joint adapter.
• Hand-thread the new plug in first, then torque: Torque to 18 N·m (13 ft-lbs).
• Reinstall coils and torque coil bolts: Torque to 12 N·m (9 ft-lbs).
• Reconnect all coil electrical connectors until they click.

Step 7: Reinstall the upper intake manifold

• Remove the shop towels from the intake ports (double-check nothing fell in).
• Install the new upper intake manifold gaskets in their grooves.
• Set the upper intake manifold back in place.
• Start all bolts by hand, then tighten evenly in a crisscross pattern using a 12mm socket.
• Final tighten with a torque wrench: Torque to 22 N·m (16 ft-lbs).
• Reconnect all hoses/connectors you labeled.

Step 8: Reinstall the throttle body and intake duct

• Install the new throttle body gasket.
• Reinstall the throttle body fasteners using a 10mm socket, then torque: Torque to 12 N·m (9 ft-lbs).
• Reconnect the throttle body electrical connector.
• Reinstall the air intake duct and tighten clamps with a flathead screwdriver.

Step 9: Reconnect battery and reinstall engine cover

• Reconnect the negative battery terminal using a 10mm socket.
• Press the engine cover back onto its grommets.

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✅ After Repair

• Start the engine and let it idle. Listen for vacuum leaks (hissing) around the intake.
• If the idle hunts or is high after reconnecting the battery, perform an idle relearn: warm the engine fully, then let it idle for 5 minutes with all accessories off.
• Test drive 10-15 minutes and confirm there’s no check engine light.
• Recheck that all intake clamps/hoses are secure once back home.

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💰 DIY vs Shop Cost

Shop Cost: $450-$750 (parts + labor)

DIY Cost: $90-$220 (parts only)

You Save: $230-$660 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 2-4 hours.

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🎯 Ready to get started?

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