🔧 Fusion - Spark Plug Replacement

Replacing the spark plugs on your Fusion helps restore smooth idle, easier starts, better fuel economy, and proper turbocharged engine performance. The 1.5L EcoBoost uses individual ignition coils on top of each spark plug, so you’ll remove the coils first, then replace the plugs one at a time.

Difficulty Level: Beginner | Estimated Time: 1-2 hours

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⚠️ Safety & Precautions

• ⚠️ Work only on a completely cool engine. Aluminum cylinder heads can be damaged if spark plugs are removed while hot.
• ⚠️ Disconnect the negative battery cable before unplugging ignition coils.
• ⚠️ Keep dirt, sand, and debris away from the spark plug wells. Anything that falls in can damage the engine.
• ⚠️ Do not use anti-seize on modern coated spark plug threads unless the plug manufacturer specifically requires it.
• ⚠️ Tighten spark plugs carefully. Over-tightening can strip the aluminum cylinder head.

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🔧 Required Tools

You'll need the following tools for this repair:

• 8mm socket
• 10mm socket
• 5/8-inch spark plug socket
• 3/8-inch drive ratchet
• 3/8-inch drive 6-inch extension
• 3/8-inch drive torque wrench
• Spark plug gap gauge
• Compressed air nozzle
• Dielectric grease
• Needle-nose pliers
• Plastic trim tool
• Clean shop towels
• Nitrile gloves
• Safety glasses

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🔩 Required Parts

HowToo sells all the parts you need for this repair:

• Spark plugs - Qty: 4
• Ignition coil boots - Qty: 4
• Intake tube clamp replacement - Qty: 1 if damaged

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📋 Before You Begin

• Park your Fusion on level ground, shift to Park, and set the parking brake.
• Let the engine cool for at least 2 hours if it was recently driven.
• Open the hood and remove any loose leaves or dirt near the engine cover.
• Use a 10mm socket to disconnect the negative battery cable, then move the cable aside so it cannot touch the battery post.
• A spark plug socket is a deep socket with a rubber insert or magnet that holds the spark plug so it does not fall.
• A torque wrench is a tool that clicks when the bolt or plug is tightened to the correct tightness.

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🔨 Step-by-Step Instructions

Follow these steps in order:

Step 1: Remove the Engine Cover

• Use both hands to lift the plastic engine cover straight upward.
• If it feels stuck, use a plastic trim tool gently at the rubber mounting points.
• Set the cover aside where it will not get stepped on.
• Pull upward, not sideways.

Step 2: Clear Access to the Ignition Coils

• Look across the top of the engine for the four ignition coils. Each coil has an electrical connector and sits over one spark plug.
• If the air intake tube blocks access, use an 8mm socket to loosen the intake tube clamp.
• Use needle-nose pliers only if needed to gently move a small hose clamp.
• Move the intake tube just enough to access the coils. Do not force plastic hoses.

Step 3: Unplug the Ignition Coil Connectors

• Use your fingers to press the locking tab on each ignition coil connector.
• If the tab is tight, use a plastic trim tool to gently help release it.
• Pull the connector straight back from the coil.
• Do not pull on the wires.
• Connector tabs can be brittle.

Step 4: Remove the Ignition Coils

• Use an 8mm socket and ratchet to remove the ignition coil hold-down bolt from each coil.
• Twist each coil slightly by hand, then pull it straight upward.
• Lay the coils in order from left to right so they go back to the same cylinders.
• Inspect each rubber boot for oil, cracks, swelling, or burn marks.

Step 5: Clean the Spark Plug Wells

• Put on safety glasses before using compressed air.
• Use a compressed air nozzle to blow dirt out of each spark plug well.
• Use a clean shop towel around the area to catch dust.
• This prevents debris from falling into the engine when the spark plug is removed.

Step 6: Remove the Old Spark Plugs

• Use a 5/8-inch spark plug socket, 6-inch extension, and 3/8-inch drive ratchet.
• Turn the spark plug counterclockwise slowly until it breaks loose.
• Continue turning by hand with the extension once it loosens.
• Lift the old spark plug out carefully with the spark plug socket.
• Remove only one spark plug at a time to reduce the chance of debris entering the engine.

Step 7: Check the New Spark Plug Gap

• Use a spark plug gap gauge to verify each new plug is gapped correctly before installation.
• For the 1.5L EcoBoost, set the spark plug gap to 0.028 inch.
• Do not pry hard against the center electrode. That is the small tip in the middle of the plug.
• If using pre-gapped fine-wire plugs, check only; avoid bending unless the plug maker allows adjustment.

Step 8: Install the New Spark Plugs by Hand

• Place one new spark plug into the 5/8-inch spark plug socket.
• Use the 6-inch extension by hand only at first.
• Turn the spark plug clockwise gently until the threads start smoothly.
• If it feels tight right away, stop and restart. Cross-threading can damage the cylinder head.
• Hand-start every plug first.

Step 9: Torque the Spark Plugs

• Attach the 3/8-inch drive torque wrench to the 6-inch extension and 5/8-inch spark plug socket.
• Tighten each spark plug to Torque to 15 Nm (11 ft-lbs).
• Do not add extra tightening after the torque wrench clicks.
• Repeat Steps 6-9 for all four spark plugs.

Step 10: Service and Reinstall the Ignition Coils

• Apply a very small amount of dielectric grease inside the end of each ignition coil boot.
• Dielectric grease is silicone grease that helps seal moisture out of electrical boots.
• Push each coil straight down over its spark plug until it fully seats.
• Use an 8mm socket to reinstall the ignition coil hold-down bolts.
• Tighten each ignition coil bolt to Torque to 6 Nm (53 in-lbs).

Step 11: Reconnect the Ignition Coil Connectors

• Push each electrical connector onto its ignition coil by hand until it clicks.
• Lightly tug each connector to confirm it is locked.
• Use a clean shop towel to wipe the area before reinstalling the engine cover.

Step 12: Reinstall Intake Tube and Engine Cover

• If moved, reposition the intake tube fully onto its connection.
• Use an 8mm socket to tighten the intake tube clamp snugly.
• Do not over-tighten the clamp because plastic intake parts can crack.
• Press the engine cover straight down onto its rubber mounts by hand.

Step 13: Reconnect the Battery

• Use a 10mm socket to reconnect the negative battery cable.
• Tighten the terminal until it is secure and cannot rotate by hand.
• Close the hood only after the engine test is complete.

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✅ After Repair

• Start your Fusion and let it idle for 2-3 minutes.
• The engine may idle slightly unevenly for a few seconds after the battery was disconnected.
• Check that no warning lights are flashing and that the engine runs smoothly.
• Listen for air leaks around the intake tube if it was removed or moved.
• Take a short test drive with gentle acceleration first, then normal acceleration.
• If the check engine light flashes, stop driving and recheck ignition coil connectors and plug seating.
• Reset the clock and one-touch window function if needed after battery disconnect.

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💰 DIY vs Shop Cost

Shop Cost: $220-$420 (parts + labor)

DIY Cost: $45-$120 (parts only)

You Save: $175-$300 by doing it yourself!

Shop labor rates vary but typically run $100-$150/hour. This repair takes a shop approximately 1-1.5 hours.

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