2006-2009 Ford Fusion Spark Plug Replacement (2.3L)

What's up everybody!
This is a DIY how-to on replacing the spark plugs on 2006-2009 1st Gen. Ford Fusion. Car in video is a 2007 Fusion 2.3L 4 Cyl., but the process should be near the same for the 2010-2012 2.5L 4 Cyl. variant. Torque Specs included.
*DISCLAIMER: I am NOT a Master Tech, just a long time wrencher.

[@TheOriginalBeeCee]

ADDITIONAL INSIGHT REGARDING VIDEO: As far as the use of anti-seize when replacing spark plugs......most plug manufacturers today state NOT to use anti-seize when installing. Although, this is a more recent revelation, 10 years ago Autozone would try and sell you an anti-seize pack with a spark plug pictured on it any time you purchased plugs lol. Many mechanics still use anti-seize when doing plugs, and I’ve personally done it on countless vehicles for over 15+ years with 0 issues. For me, this article pretty much sums it up: agradetools.com/be-confident-with-anti-seize-how-to-use-the-right-anti-seize-like-a-boss/ ..Basically as the article is stating, if you have a bunch of people overtightening their lubricated spark plugs from inexperience & stripping out their engine heads....the plug manufacturer could be held liable. By telling you not to use anti-seize they reduce their liability, and they wouldn’t be held responsible for you over tightening their plugs. I think experience is a huge factor with the use of anti-seize, and obviously if it’s going to be used, moderation is the key to success for its use. Less is more. Only a small coat around the center threads is necessary, you don’t want to affect the plugs grounding abilities by drenching it with anti-seize. An issue that can arise from using too much anti-seize is that it gets into the combustion chamber area where is could potentially short out the electrodes. In hindsight......considering a lot of people watching this probably don’t have a ton of experience with plugs/anti-seize...I felt I at least should share a disclaimer that anymore plug companies don’t suggest it use. For me, it’s more or less habitual at this point, and in most cases I’m sure you could get away without using it, but for certain applications I still think it serves a purpose when used modestly. A general rule many consider when choosing to use anti-seize is if the plug has an anti-seize plating (chromey looking finish), do not use it. If the plugs have a dull iron or black finish on the threaded area, it’s ok to use anti-seize. In my opinion, the use of anti-seize is optional and a matter of preference, and with or without its use a spark plug job can be done successfully.

[@karenalmestica739]

Dang, you reassured us it wasn't your car but the neighbors. 😂😂😂😂

[@karenalmestica739]

8:00 - the struggle was real on that second one. 😂😂😂 Overall well done !!!

[@TheOriginalBeeCee]

Lol gotta let the facts be known!!

[@indyfosho5458]

Mine is 07. 190k. Just had to change the plugs for the first time today. 07 2.3 fusion best damn car ever, and best to work on. They all looked fine also tbh. Gap was still good and were pretty clean. Only plug I had trouble removing was #3 With that said, I think my problem are the coils and were not the plugs. That's tomorrow....

[@slappy200]

Excellent vid, also appreciate the recommended spark plug gapping. Cheers!

[@TheOriginalBeeCee]

🙏🙏🙏🙏

[@richardmclay2536]

Thank you!!

[@pranker901]

This was a great video! Any tips if the spark plug won't even budge? I'm contemplating a breaker bar or just saying screw it and leaving it in there.

[@TheOriginalBeeCee]

Thank you! One thing you can try is shooting a small bit of PB Blaster/penetrating oil on it, and let it soak for a bit. Don’t go crazy with it, just enough to let a bit of oil make its way to the threads. I would try to let it sit as long as you can. Maybe even do a small about, let it sit for an hour, do another small amount, then come back a few hours later and give it a try. You could try a breaker bar, but I would be extremely careful doing so and really would try to avoid it if you can. You might even wanna try to work your way up to it, starting with smaller tools if you have them available...like a longer 3/8 drive ratchet, if that doesn’t work maybe a small 1/2 drive, if that doesn’t work try a longer handle 1/2, etc. working your way up to the breaker bar if need be.

[@pranker901]

@@TheOriginalBeeCee I'll give this a shot. I'll definitely slowly work my way up. A broken spark plug is my worst nightmare haha

[@TheOriginalBeeCee]

@@pranker901 yeaa man a broken plug is definitely nightmare status lol. Good luck though!

[@user-wk9ow1uz1l]

What's the cable connected to the sparkplug 2nd from the left

[@tommyjoe136]

Should have checked for oil before removing the plug. The black ring on the plug lets you know the oil was on topside. Take a clean rag a remove the oil before removing the plug.

[@TheOriginalBeeCee]

There was no oil to be removed before removing the plug. The plug wells were not filled with oil. This wasn’t a overly drastic VCG leak. Yes, the plugs were oily, but that doesn’t mean there was a puddle in the spark plug well. And if you were watching the video closely enough, the first coil i pulled (@1:45) was indication of that, it was bone dry. Just because oil is getting past the plug tube seal, doesn’t mean the well is filled with oil. The oil was not prominent until the plug was removed, you can also verify that by paying attention to the spark plug socket when i pulled out a plug, if the tube was filled with oil the socket would have been covered and dripping it oil. So what you’re suggesting might apply to some instances, but not the one in the video. I appreciate you trying to find something wrong with the video though.

[@lukek8140]

I followed all the steps for my '06 Fusion, and everything went fine. But when I turned the car on the exhaust is expelling white smoke that smells fuel rich. I double-triple checked all my steps from start to finish, and everything there seemed fine. I'm not finding much help online elsewhere as to what is causing the smoke. Do you have any insight? I appreciate the help!

[@TheOriginalBeeCee]

I’m sorry, I know I’m super late...but I’m just now seeing this comment. Sometimes I don’t get notifications from KZbin with comments. Did you ever get it sorted?

[@lukek8140]

@@TheOriginalBeeCee I did, thanks. Eventually the smoke cleared on its own. I called my Captain at work who is very knowledgeable on cars and engines, and he thinks the engine was just burning off some residual leftover from the work being done. Essentially, the car needed to "clear its throat."

[@TheOriginalBeeCee]

@@lukek8140 ok awesome. Was hoping it was just something like that, glad thats all it was 🙏

[@ryanwilcox1209]

My 06 fusion is at 234,000 miles and I think it's probably on it's original spark plugs. Hopefully this will improve my gas mileage

[@TheOriginalBeeCee]

Sheesh thats some mileage for original plugs!

[@civi_mane_318]

do you need to empty the well if the spark plugs are drenched in oil?

[@TheOriginalBeeCee]

I would roll a paper/shop towel up tight, the size of the cylinder, and carefully guide it into the well and turn it around until you start soaking some up. You might need to use a few different towels to get it 100 percent.

[@MilesPrower1992]

Mine doesn't have that air duct over the engine, should it? Mine is a 2008

[@TheOriginalBeeCee]

Yea it definitely should have it. Maybe someone in the past removed it and never re-installed it. You can probably source one cheap from a junkyard or eBay to get it back to OE

[@seppukug5996]

It becomes obsolete if you get a after market alternator 🤷‍♂️

[@MilesPrower1992]

@@seppukug5996 I just sold the car instead because it wouldn't start below -10 degrees

[@Loudes012]

@MilesPrower1992 Got the same car 08' S trim. Looks like you used Motorcraft spark plugs.Those probably are the best.

[@nickkkyss7634]

Does it make a difference what kind of brand of spark plugs? I have 06 my self

[@TheOriginalBeeCee]

That’s kind of a subjective question, and a matter of preference, as they’re are variety of plug brands both great and not so great. Personally, I like using whatever the car was originally equipped with, the exact original plug, down to exact part number even..if possible. But that’s not to say other plugs won’t work as well.

[@nickkkyss7634]

Alright thx a lot man !!!

[@ricardovargas1526]

MOTORCRAFT

[@margaretwilson3644]

mine a 2009 and doesn't have the cover thing over it

[@michaelbrukley1311]

I always find spark plugs 100 times easier when the engine is hot

[@TheOriginalBeeCee]

Sheeesh man. Do some research. Thats a big no no.

[@TheVexetta]

"she is extremely tight"...

[@zeroquanta4252]

Seems if they are VERY TIGHT,,, Warm Car up witch with Expand engine, and help the sparkplug to come out..

[@TheOriginalBeeCee]

That’s actually something that you should try to avoid at all costs. Attempting to remove the spark plugs from a hot engine can cause the spark plug threads to seize/warp and cause damage to the cylinder head threads. The proper seating of the new spark plug can be affected from doing this when going to reinstall.

[@zeroquanta4252]

@@TheOriginalBeeCee Thanks for reply,,, I would have tried that,,,, Not now,, thanks

[@TheOriginalBeeCee]

@@zeroquanta4252 🙏🙏🙏

[@loganwork7024]

My first gen fusion is a manual. Its also a shit box at this point. Don't buy a ford fusion.

[@TheOriginalBeeCee]

Lol

[@ryanwilcox1209]

I absolutely love my 06 Ford fusion! It runs fantastic

[@nicholasbabeaux2052]

Dude these are as reliable as Toyota Camry’s, yours must’ve been not maintained very well, they run forever, only major issues is the thermostat, and you just Gotta keep up with the maintenance

[@heatedbadge97]

Mine cost me 4k in repairs😅