DIY repair · Isuzu Trooper (second generation)

Replace the intake plenum and manifold gaskets

DIFFICULTY 3 / 5TIME A dayCOST Parts plus labor

Symptoms

Stalling when slowing or at a stop, a rough idle, a check-engine light and, in one NHTSA report, fuel-fouled spark plugs.

The fix, step by step

  1. Disconnect the battery and remove the intake cover and air intake.
  2. Label and disconnect the vacuum lines, wiring and throttle linkage, unbolt the upper plenum, then the lower intake manifold if it's leaking too.
  3. Clean every sealing surface without gouging the aluminium, fit new gaskets, and torque the bolts in the factory sequence.
  4. Replace the plugs if they're fouled and clear any stored codes.

Tools & part numbers

  • Socket set with extensions
  • torque wrench
  • plastic scraper
  • masking tape for labels
  • factory torque sequence confirm in manual.

Where to buy the parts

Intake plenum gasketRockAuto ↗Amazon ↗
Intake manifold gasketRockAuto ↗Amazon ↗

Hunting a used or discontinued part? Search eBay Motors for Isuzu Trooper (second generation) parts →

Before you start

Rated for a competent home mechanic with a decent tool kit. Confirm torque figures, fluids and procedures against the factory service manual for your VIN, support the truck on stands rather than a jack, and work at your own risk (disclaimer). Some parts links are affiliate links, which pay us a small commission at no cost to you.

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