🔧 Fusion - Ignition Coil Replacement

Your Fusion uses a coil-on-plug ignition system (one ignition coil per spark plug). Replacing the coils restores strong spark and can fix misfires, rough idle, and poor acceleration.

Difficulty Level: Beginner | Estimated Time: 0.5-1.0 hours

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⚠️ Safety & Precautions

• ⚠️ Work on a cool engine to avoid burns.
• ⚠️ Disconnect the negative battery cable to prevent accidental shorts.
• ⚠️ Don’t pull on wiring—only pull on connectors.
• ⚠️ Keep dirt out of the spark plug wells (the deep holes the coils sit in).

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🔧 Required Tools

You'll need the following tools for this repair:

• Safety glasses
• Nitrile gloves
• 10mm wrench
• 1/4" drive ratchet
• 1/4" drive extension (3" to 6")
• 8mm socket
• Torque wrench (inch-pound)
• Small flathead screwdriver
• Compressed air blow gun
• Shop rags

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Ignition coil - Qty: 4
• Dielectric grease - Qty: 1
• Optional: Spark plugs - Qty: 4

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📋 Before You Begin

• 🧰 Park on level ground, shift to Park, and set the parking brake.
• 🧰 Let the engine cool fully.
• 🧰 Open the hood and disconnect the negative battery cable using a 10mm wrench.
• 🧰 Dielectric grease is non-conductive boot lubricant.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Remove the engine cover (if equipped)

• Grip the cover and pull straight upward to release it from the rubber grommets.
• If it feels stuck, gently pry up at a corner with a small flathead screwdriver.

Step 2: Clean around the ignition coils

• Use compressed air blow gun to blow debris away from the coil bases and spark plug wells.
• Keeping dirt out prevents plug/well damage.

Step 3: Unplug an ignition coil connector

• Locate one coil (there are 4, one per cylinder).
• Release the connector lock tab using a small flathead screwdriver if needed, then unplug the connector by hand.
• Wipe the area with shop rags if oily or dusty.

Step 4: Remove the ignition coil hold-down bolt

• Use an 8mm socket, 1/4" drive ratchet, and 1/4" drive extension (3" to 6") to remove the coil bolt.
• Set the bolt aside where it won’t get lost.

Step 5: Remove the old ignition coil

• Twist the coil gently left/right by hand to break it loose.
• Pull straight upward to remove it from the spark plug well.
• If it’s stubborn, keep twisting gently—don’t pry hard on the valve cover.

Step 6: Prep and install the new ignition coil

• Apply a small, thin smear of dielectric grease inside the new coil boot (the rubber “cup” that seals on the spark plug).
• Push the new coil straight down until it fully seats on the spark plug.

Step 7: Reinstall and torque the coil bolt

• Start the bolt by hand to avoid cross-threading.
• Tighten using an 8mm socket and 1/4" drive ratchet.
• Finish with a torque wrench (inch-pound): Torque to 7 Nm (62 in-lbs).

Step 8: Reconnect the coil electrical connector

• Push the connector on until it clicks/locks.
• Gently tug to confirm it’s secure.

Step 9: Repeat for the remaining coils

• Repeat Steps 3 through 8 for the other 3 coils.
• Do one coil at a time to avoid mix-ups.

Step 10: Reinstall engine cover and reconnect battery

• Reinstall the engine cover by pressing it straight down into the grommets.
• Reconnect the negative battery cable using a 10mm wrench.

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✅ After Repair

• ✅ Start the engine and let it idle for 1-2 minutes. It should run smoothly.
• ✅ If the check engine light was on, clear codes with a scan tool, or it may clear after a few drive cycles if the issue is fixed.
• ✅ Test drive 10-15 minutes and recheck for any misfire, flashing check engine light, or fuel smell.
• ✅ If a misfire remains, the next most common cause is worn spark plugs.

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💰 DIY vs Shop Cost

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

DIY Cost: $120-$400 (parts only)

You Save: $130-$250 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 0.7-1.0 hours.

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🎯 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.