How to remove the Intake Manifold, and replace coils & spark plugs on a 2006 Mercury Montego 3.0L V6

My 2006 Mercury Montego had a misfire coming from cylinder #3 (Code P0303). In this video I show how I removed the upper Intake Manifold to get to the coils and sparkplugs, replace the coils and sparkplugs, and replace the Intake Manifold and throttle body gaskets. I also include tips and other related how to's.
PARTS FOR 2006 MERCURY MONTEGO 3.0L V6:
Ignition Coils, Part # Motorcraft- DG 513 - www.amazon.com/gp/product/B00...
Spark Plugs, Part # Motorcraft SP-433 - www.amazon.com/gp/product/B00...
Swivel Magnetic Spark Plug Socket, 3/8 Drive - www.amazon.com/gp/product/B07...
27 mm 12-point Metric Wrench - www.homedepot.com/p/Husky-27-...
Drive Socket Set, 3/8" - www.amazon.com/gp/product/B07...
3/8" Drive Extra Long Torx Star Bit Socket Set (T10 to T40) - www.amazon.com/gp/product/B00...
Intake Manifold Gasket Set MS92586 - www.amazon.com/gp/product/B07...
Throttle Body Mounting Gasket, Fel-Pro 61377 - www.amazon.com/gp/product/B00...
Dielectric Tune-up Grease - www.amazon.com/gp/product/B00...
Anti-seize lubricant, Loctite 495556 - www.amazon.com/gp/product/B00...

[@mrfast1esmc]

As an ASE certified master tech for 40 years you nailed it !!!! If I wasn't retired you would be my first pick for a new hire. You are very patient and well in explaining your process. In today's day and and age with all the complicated repair routines and bogus repair videos I salute you !!!! Fast Eddie in New Jersey

[@Chocaluvr]

Fast Eddie from New Jersey, THANK YOU! I needed to hear that today! I put a lot of research into it before making this video since it was my first time removing an upper intake manifold. I've worked on my other cars but not so much on this one. FYI... I was raised in New Brunswick. :)

[@czarjodon9593]

Well finally a video that’s really well put together explaining the process, giving tips, tools needed, how to remove hoses and their functions. Overall one of the best videos I’ve seen… 👏🏼👏🏼👏🏼

[@Chocaluvr]

Thank you for watching and your comment!

[@KaveMahn]

This is one of the best put together instructional videos I’ve seen. I used this to fix my mom’s car. Thank you for all the detail you put into this.

[@Chocaluvr]

Awww thank you! That made my day!

[@Aint_no_senators_son]

Your video was better than many of the men you see on here who are MECHANICS! Thank you!

[@Chocaluvr]

Thank you!!!

[@Aint_no_senators_son]

Well thanks to you I got up the courage to tear into mine yesterday. I'm a decent shade tree mechanic but I hate anything built after the 80s. Especially front wheel drive. I got the intake off and now waiting on coil packs and plugs since my local parts store only had one coil pack. I ordered them off Amazon. I used a 15/16 wrench on those mount bracket bolts and I got very lucky on the EGR valve. It wasn't that tight. I used a standard wrench. I think a 1 1/8. Hope it goes back together as easy as I got it apart. Thank you again.

[@Chocaluvr]

That’s great! I’m happy to hear you had no trouble loosening that EGR nut. Everything should go back together easily from here on. There’s nothing like the satisfaction and feeling of accomplishment when you do it yourself.

[@Aint_no_senators_son]

@@Chocaluvr I live in the south so usually bolts aren't that hard to deal with unless it was a northern car. My friend from Indiana moved here and was shocked at how clean the cars are. I got it finished today. It went back together easier than it came apart. Another piece of advice I would offer is buy some bright green painters tape. I keep some in my toolbox. Mark all the hoses with the tape and write on it where they go. Also I use toolbox tray organizers to keep my bolts separate when I work on stuff. Just write what the bolts go to on some tape and stick it in the bottom of that section. That has worked so well for me over the years. And as you said, pictures! Lots of pictures from every angle. Close up, zoom out, etc. Thank you again! You did an awesome job.

[@Chocaluvr]

Great tips. Thanks!

[@The.Home.Cinema.Engineer]

I have the same car and im doing the same stuff now! Thanks for the video Its cool to see people doing diy stuff and save money!

[@me-gg6xm]

you had your troubles, but i am glad you did it yourself. great job.

[@gods959]

Thank you for sharing your knowledge. You're a blessing ☺️🙏❤️❤️❤️ I'm 58 and yes you have motivated me 👍

[@Chocaluvr]

You are welcome! 😊

[@gods959]

@@Chocaluvr My oldest daughter and I just fixed her car , Saturday it was the proudest moment of my life. She started out slow , but I told her look at this Lady and mimic everything that she does and she did better than expected. All because of you. ❤️❤️❤️ Stay blessed because you truly are a blessing ☺️🙏 Love you so much for sharing 👍 God bless you and your family in Jesus name Amen

[@kaceyk2171]

Love to see another female mechanic at it! Especially making such well put together videos like yours! Huge props!

[@ThurmondGoins]

I love when that car cranked up like a new motor.😮❤

[@billyeldridge1929]

Hey you did a great job you explained everything in detail and that mechanic should be run out of business that was outrageous. Great job great video

[@Chocaluvr]

Thanks for watching and your comment!

[@billyeldridge1929]

@@Chocaluvr it was a great pleasure to watch. SEMPER-FI

[@adtynkr]

That EGE valve nut is the bane of my existence! I haven’t been able to get it off. I feel like seeking off the car.

[@Chocaluvr]

I know what you mean! It took me 3 days fighting with it. Remember to loosen the nut like I showed in the video. Try soaking a rag with WD40 and wrap it around the nut overnight. Some people have suggested using a torch to heat it up.

[@adtynkr]

@@Chocaluvr I soaked it in wd40 overnight but still couldn’t remove it. But I went another way and removed the two bolts on either side on top of the egr valve and was finally able to lift off the intake manifold but it was surely more harder. I had to loosen the black metal line on the left though because it was blocking the left edge of the manifold. I saw the next morning that there was tons of orange/pink oil on the ground that came out of that line. What is that line and is something I need to worry about?

[@Chocaluvr]

@@adtynkr I believe that's a power steering line you are talking about, there's also a vacuum hose there if I remember, but anyway, check your power steering fluids and all the other fluids when you put everything back because when you start removing hoses, you'll have leaks.

[@adtynkr]

@@Chocaluvryes you’re right! That’s my power steering fluid all over the ground. The power steering fluid reservoir is empty. Seems like the line going down into the steering pump is bent and leaking 😢. This is turning into a nightmare.

[@Chocaluvr]

@@adtynkr I’m sorry to hear that. It’s probably easy to replace by checking junk yards in your area for the part. I too ran into my nightmares when fixing things. It happens unfortunately. 😞

[@optimumwashleaders8189]

You have heart and determination, which are both motivating! Thanks for sharing and wish me luck😜🤙🏽

[@Chocaluvr]

Good luck!! 😁

[@johnbiavaschi1829]

This is something I read on a Ford forum about the EGR valve: “I did find out you don't have to remove the EGR valve! There are two bolts that connect the ERG valve to the Plenum that when removed separate the two, then the intake manifold may be removed. Much simpler than taking off the large nut holding the entire EGR valve. Hopefully this will be a help to those trying to remove their intake manifold”.

[@Chocaluvr]

Yeah, others have suggested it. I’ve also read from others that have done that is that those two bolts can be difficult to loosen. One comment I read from someone who did that was that they had trouble with the car throwing off codes after they separated the EGR valve. Once you separate the EGR valve from the plenum, the gaskets should be replaced and some people don’t think of doing that. Either way, it’s too much trouble to get to the coils and spark plugs the way this car was designed.

[@johnbiavaschi1829]

I was thinking about the possibility of causing vacuum leaks by removing the EGR valve that way too. My 2007 Mercury Montego Premier has almost 106K miles on it, I think I’m just going to see how far it goes.

[@Chocaluvr]

@@johnbiavaschi1829 I feel that if you go into it knowing that there may be some risks and be prepared to deal with it, you’ll be okay. If you decide to go via the EGR way, just be ready with replacement gaskets. It’s a pain in the rear but is doable. I never thought I would accomplish this when I started it but stuck with it and I’m glad I did. Car runs so much better 😃

[@rokuronzoni6274]

Thanks so much for filming this. *ford 500 secret handshake*

[@connerlester4896]

Just finished replacing the back coils and spark plugs and I just wanted to let you know you are a blessing. Wouldn’t have been able to do it without you😂❤

[@Chocaluvr]

Awww, I’m glad I was able to help. Thank you!

[@rickomaples1]

Excellent video! Kudos to you!

[@mrfast1esmc]

OOH !!! A Joisey Gal !!!! Luv it even more !!!!!

[@michaelisangeluskaiser556]

Best mechanic howdy from Texas God bless you

[@bradleygoins380]

Great job for your first time.

[@Chocaluvr]

Thanks!

[@bigwaves2824]

great video

[@scottcollins7774]

Thanks for sharing😮❤

[@MultiUnitPros]

Great share. Thanks it help a lot.

[@river86012]

Good video.. thanks!

[@Chocaluvr]

You are welcome! Thanks for watching.

[@Dennis-sb7gp]

GOOD JOB

[@StarDeSoul]

@11:35 explaining that the EGR valve nut loosens to the right instead of left is probably the MOST helpful tip that isn't in any other videos I've watched!! This video the most comprehensive and clear with all the steps I'll need to follow. As a single disabled mom on a tight budget that can't afford to pay a man to do this, it's very encouraging to watch a video made by a woman that is comfortable admitting which parts were a struggle! Also, I'd been trying to figure out what the rotted rubber part was called that needed replacing in the middle of that motor mount in the middle so I could order one; you called it a TORQUE STRUT MOUNT/BUSHING. Now I am more confident that I can handle this repair myself even if it takes me several days. Thank you so much!💞

[@Chocaluvr]

You are welcome! Don’t worry about how long it takes; it took me days to do it myself. We’re in the same situation. Here’s the link to the bushing I got. Make sure it fits your car. I have another video showing how I did this also. www.amazon.com/gp/product/B00FLFVLH0/ref=ppx_yo_dt_b_asin_title_o02_s00?ie=UTF8&psc=1

[@secondlifebikes80]

Yes, I think if you look at it from the top, then yes, it would appear you have to turn the wrench clockwise. But if you look at it from the nut's point of view, it screws tight upwards toward the EGR valve, so in that point of view, it's still right-hand thread and it would loosen counterclockwise (normal) so it's not technically reversed threading, just point of view.

[@jakemerle7239]

Thank you!

[@paulshoger5099]

Great job on the video! Used it as a reference to replace spark plugs on my "07 Freestyle

[@Chocaluvr]

Thanks!

[@deronjurgensen6412]

Wows isn’t it crazy what you need to do to change the spark plugs. Unreal, I can hear my dad cussing the engineers on this one.

[@Chocaluvr]

Yeah, I did a little of that off camera 😂

[@secondlifebikes80]

@4:03 and after, you said brake fluid, it's coolant. I think that's what you meant... nice video!

[@Chocaluvr]

Thanks but it was break fluid I found on the floor and the brake fluid canister was almost empty.

[@leroyrcrumjr9368]

Thank you good video

[@Chocaluvr]

Thanks for watching!

[@candlestyx8517]

All of this nonsense just to replace spark plugs. I got stuck on the EGR nut for a couple days until I hit it with some Ballistol and a torch. I also had to remove the battery and the box to get more room for the wrench. I kept telling myself "Id really love to slap the team of engineers who designed this engine".

[@Chocaluvr]

I agree!!! The EGR nut had me going nuts! Did you see where the engineers placed the alternator? Halfway down underneath the throttle body! Old Fords had them on the passenger side at the top. Well, at the cost of my sanity to replace 6 spark plugs, I saved myself nearly $1000 from a mechanic that thought he was going to rip me off because I’m a woman.

[@candlestyx8517]

@@Chocaluvr Yeah, they certainly don't build them for ease of repair anymore. They make them as hard as possible to work on, so you have to bring them back to the dealership. It's all designed with profit in mind first, then reliability, then ease of repair. Nice to see a lady who isn't afraid to turn some wrenches, break her back a little and get her hands dirty, there aren't many of you around. :) Blessings to you Choca!

[@Chocaluvr]

Thanks! Blessings to you as well. Being a single mom has forced me to learn to do many things on my own.

[@zechscott9554]

i gave up on that stupid nut and just unbolted the 10mm's that hold the egr valve gasket face to the pipe that goes into manifold. but now i'm worried about air leak when i put it back together. completely idiotic design

[@candlestyx8517]

@@zechscott9554 The engine is reliable but the design is terrible.

[@cuddlycuddlycactus2999]

amazing

[@royfritz3621]

Thank you

[@truthisnow2896]

Hi. What oil type you use? It calls for 5w- 10. Should higher milage use high type?

[@ivonlopez9999]

For older cars I've been told higher is best. I've used 10W 20 or 10W 30

[@scottpowell5227]

I have to do this also but I have to go barrow the tools do you remember what size wrenches and sockets you used and any other tools it took to do this

[@Chocaluvr]

I can’t remember all the tools I used but I left links with all the parts and tools I used. Here are the main tools I used that I can remember. You are going to definitely need a 27 mm or 1 - 1/16 inch wrench for the EGR nut. Also you will need an 8 mm and 10 mm deep socket bits for the bolts holding the intake manifold and throttle body. You can use a big adjustable wrench to remove the two big bolts holding the cross bar. I believe I used a T-20 star driver to remove the star screws inside the intake manifold. I hope this helps. Good luck!

[@scottpowell5227]

Thanks

[@i-55southstl55]

I just did a valve cove job on my infiniti m35 it was extremely difficult. Now I'm doing a valve cover job on my mercury montego. I wanna congratulate you. You did a real good job 👏

[@Chocaluvr]

Thank you! Have fun with the valve cover job. 👍

[@truthisnow2896]

You are tough!! 🤎🤎

[@bradleygoins380]

This is a great little engine.. until there's problems on 1 2 or 3 lol.

[@Chocaluvr]

Yup! That’s why I replaced all three. When one goes, the others usually follow.

[@michaelisangeluskaiser556]

❤️ 💙 💜 💖 I got stuck same egr valve part spraying it spraying it..its reversed

[@Burton007]

What happens if you don't take the bolts for the intake manifold off in order

[@Chocaluvr]

If you already tightened the bolts out of sequence, I wouldn’t worry as long as the surfaces meet smoothly with each other.

[@Burton007]

So I got scared midway through and didn't take the intake manifold off but I did loosen that bolt and I left it three threads loose. Will try that and replace the gasket on the throttle body

[@SebastianParamo-wr8gu]

What is the order of the ignition coils/cylinder? Cylinder 3 on my 2006 Montego is misfiring so if I don’t have to remove the manifold that would be awesome lol. Great video by the way I atleast know if I have to remove the manifold I’ll know how thanks to you

[@Chocaluvr]

I hate to tell you this but if you have the same engine as mine, your Cylinder/coil 3 is under the Upper Intake Manifold. You’ll have to remove the manifold. I suggest you replace all 3 coils while you’re there because when one goes bad, the others follow. I replaced all 3 coils on my car not just #3.

[@bigronnie1419]

Sounds like it would be just as easy to pull the engine and put plugs in it

[@teebin5280]

Do need buy gasket and where can I get one

[@Chocaluvr]

Yes. Everything you need is listed in the description with links to where I got mine.

[@robertleggs284]

I LOVE YOUR VIDEO ..WE...DAMN...NEAR SOUL MATES.. ...LUV

[@truthisnow2896]

I have same car. I notice lots of pinging. Can this be bad plugs?

[@Chocaluvr]

Bad spark plugs can be one of the reasons but try changing your gasoline to a high octane gas first and see if it helps.

[@truthisnow2896]

@@Chocaluvr I use 87. GAS i read it suggest 89 what do you use?

[@Chocaluvr]

@@truthisnow2896 I use both. I alternate.

[@maureenkercher4055]

After watching your video and hearing what you did, I knew I could do it too. I am in my 60's and appreciate your courage!! My vehicle is a little different, but I did it. THANK YOU!!!

[@Chocaluvr]

I’m in my 60’s too and though I’ve done repairs in my car in the past, this was the first time doing this on my car. I am cheering for you! Awesome! YOU did it!! 👏👏👏👏🙌🙌🙌

[@paullouthan4390]

Great video. I've got 2006 Ford Five Hundred that recently started misfiring. Perhaps this video will help me try to perform the repair myself.

[@Chocaluvr]

Thanks for watching and your comment. I wish you success!

[@princessfire7209]

I don’t know what happen but my car is shaking even more then it was before He changed spark plugs and I don’t know if he even changed the coil it was a cylinder 2 misfire so he was supposed to remove the intake wich he says he did but I’m not to sure now . My car is worse then before I had it fixed

[@Chocaluvr]

Have someone check it out for misfires. Autozone or any other auto parts store can check it out for free. It could be a number of things. Sometimes if you don’t put things back together right, for example and EGR valve, it can cause problems. Have someone else check it out, then take it back for them to fix the problem.

[@DeadKoby]

This is also applicable to the Ford 500... the Mercury's brother. When working well, I really love my car. I had over 100k miles on the factory plugs, so I set out to replace them as maintenance.

[@c.518]

I replaced throttle body last year. and just recently put in a new egr last month to get rid of a p0108 code. No light for a month. Now i have p0402 today. Sigh... i heard that if i clean intake manifold it might fix it. Ford 500

[@Chocaluvr]

It sounds like the EGR is still the problem. It could be something as simple as carbon holding the EGR valve stuck open or a temperature sensor. You can try cleaning the EGR valve & replacing it’s gaskets to see if it clears the code. Check to see if it was installed correctly and there are no leaks in the vacuum hoses. When they replaced the EGR, did they check the EGR pressure transducer? Some of these things you can do on your own before spending any money on replacements. Good luck!

[@c.518]

@@Chocaluvr thank you. It was me who installed new egr. I thought i did it right. Afterward, since the battery was disconnected, it reset cars memory, naturally. The light never came back on, until today, over 30 days later. Also, a strange thing, 7 monitors are ready on the car, but the final one hasnt been ready yet. After a month of driving. This has never happened before. It's disheartening to fix an issue only to get another. Garages don't wanna work on the car, so i do it myself.

[@Chocaluvr]

@@c.518 go back to your installation to check for leaks and visible carbon pieces that can be cleaned out. While you’re at it, clean the throttle body. They get dirty quickly. 👍

[@c.518]

@@Chocaluvr thanks. Will do. I just returned the 1 1/16 wrench 2 days ago at the autoparts store. That egr bolt is wild. Thinking i will never need it, but also low on cash. I think i jinxed myself 😅

[@Chocaluvr]

@@c.518 Nah, you didn’t jinx yourself. It happens and it’s frustrating and a nuisance. But that’s how we learn.

[@scottcollins7774]

God bless u and u tube .i would have torn it all apart and been bumn...😮😅❤🎉

[@michaelisangeluskaiser556]

You are real great woman ❤️ 💙 💜 💖 💗 ❤️ 💙 💜 💖 💗 ❤️ 💙 💜 💖 💗

[@Burton007]

Well I fixed the misfire but now iam leaking air somewhere it seems like

[@Chocaluvr]

If you removed the EGR valve, did you replace the gaskets in the EGR valve? Did you tightened correctly the nut underneath the EGR valve when you put everything back together? I would start checking the EGR valve area.

[@mem1701movies]

I’ve seen this done on a FORD 500 and so unnecessarily complicated

[@Chocaluvr]

I agree!

[@skyhawk21]

Why did you film in portrait instead of landscape??? Can’t see anything Your doing for help because of portrait mode

[@Chocaluvr]

It was my very first video and I was new to filming. I didn’t realize I was rolling in portrait mode until it was too late.

[@birddog3130]

Sorry can't stand a Half of a picture...bye.

[@Aint_no_senators_son]

Well bye.