Question about 2002 Isuzu Trooper

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I have a 2002 Isuzu Trooper and I'm trying to install a new upper intake gasket. To get to it, there are six black plugs (fuel injector plugs?) that need to be pulled up... Do the have O rings or can I just use a little force and pull them up?

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They have o rings but you pull them gently up out of each hole... wouldn't hurt to replace the o rings on the injectors later.

Posted on Apr 18, 2009

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I have a 2006 PT Cruiser. It keeps coding a P304. 4th cylinder misfire. I have replaced plugs, wires, coil, upper and lower intake gaskets. Its still coding and now the ck engine light blinks. Any...


CLEAN FUEL INJECTORS SEE IF THAT HELPS.IF NOT COULD HAVE BAD FUEL INJECTOR OR FUEL INJECTOR ELECTRICAL CONNECTOR COULD HAVE A SHORT.DO A COMPRESSION CHECK ON THAT CYLINER COULD ALSO HAVE LOW COMPRESSION DUE TO BAD VALVES OR INTAKE MANIFOLD LEAK AT CYLINDER NUMBER 4.

Jul 12, 2011 | 2002 Chrysler PT Cruiser

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I have a 2002 isuzu trooper (diesel) which is has its oil newly changed. last year, i complained to the dealer that it had no power and thick black smoke was emitting from it. then they replaced the...


Sounds like injectors are plugging up. Run a bottle of Diesel fuel system cleaner w/your next tankful. It might take two times but injectors get gummed up easily.

Feb 24, 2011 | 2002 Isuzu Trooper

1 Answer

Do I have to take the top in take manafold off to tighten the lower intake manafold on a 1993 buick regal 3.8 L engine?


Yes you do, the following info explains the necessary procedure.



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  1. Properly relieve the fuel system pressure.
  2. Disconnect the negative battery cable. Place a clean drain pan under the radiator, open the drain **** and drain the cooling system.
  3. Remove the air cleaner assembly and the fuel injector sight shield.
  4. Disconnect the cables from the throttle body and mount bracket.
  5. Remove the coolant recovery reservoir.
  6. Remove the inner fender electrical cover on the right side.
  7. Remove the right rear crossover pipe heat shield.
  8. Disconnect the fuel lines from the fuel rail and from the cable bracket.
  9. Remove the alternator and brace.
  10. Remove the throttle body cable mounting bracket with the vacuum lines and disconnect the vacuum lines.
  11. Tag and detach the electrical connections at the throttle body and both banks of fuel injectors.
  12. Disconnect the vacuum hoses from the canister purge solenoid valve and transaxle module and intake connection.
  13. Unbolt the power steering pump and move forward. DO NOT disconnect the fluid lines.
  14. Tag and disconnect the spark plug wires position lay aside.
  15. Disconnect the coolant bypass hose from the intake manifold.
  16. Remove the solenoid valve mounting bracket and power steering support brace from the intake manifold.
  17. Disconnect the heater pipes from the intake and front cover.
  18. Remove the alternator support brace from the intake.
  19. Disconnect the upper radiator hose from the housing.
  20. Remove the thermostat housing and thermostat from the intake.
  21. Detach the electrical connector from the temperature sensor and sensor switch.
  22. Unfasten the intake manifold bolts, then remove the manifold as an assembly. Remove and discard the gaskets.
  23. If separating the upper manifold from the lower, proceed as follows:
  24. Remove the fuel rail and fuel injectors.
  25. Detach the coolant sensor switch.
  26. Remove the manifold end cap cover.
  27. Remove the upper intake manifold and throttle body assembly from the lower manifold. Remove and discard the gaskets. To install:
  28. Thoroughly clean all gasket mating surfaces.
  29. If replacing the upper manifold, proceed as follows:
  30. Apply a 1⁄16 in. bead of Loctite® Instant Gasket Eliminator 51845 or equivalent to the lower manifold mating surface. Make sure to circle all bolt holes.
  31. Carefully lower the upper manifold and throttle body assembly onto the lower manifold.
  32. Tighten the upper manifold retaining bolts to 19 ft. lbs. (26 Nm).
  33. Install the manifold end cap cover and the coolant sensor switch.
  34. Install the fuel injectors and rail to the manifold assembly.
  35. Clean the mating surfaces and install the intake manifold gaskets and seals. Apply sealer to the ends of the of the intake manifold seals.
  36. Position the intake manifold and apply a suitable thread lock compound to the bolt threads. Tighten the retaining bolts to 88 inch lbs. (10 Nm), twice, in the sequence shown in the accompanying figure.
  37. Attach the electrical connector to the temperature sensor and sensor switch.
  38. Install the thermostat housing and thermostat with a new gasket.
  39. Connect the alternator support brace to the intake.
  40. Install the solenoid valve mounting bracket and power steering support brace to the intake manifold.
  41. Connect the heater pipes to the intake and front cover.
  42. Attach the coolant bypass hose to the intake manifold.
  43. Install the power steering pump support bracket and tighten to 37 ft. lbs. (50 Nm).
  44. Install the spark plug wires on both sides.
  45. Install the belt tensioner pulley and tighten to 33 ft. lbs. (45 Nm).
  46. Install the power steering pump.
  47. Connect the vacuum hoses to the canister purge solenoid valve and transaxle module and intake connection.
  48. Attach the electrical connections at the throttle body and both banks of fuel injectors.
  49. Install the alternator and brace.
  50. Connect the throttle body cable mounting bracket with the vacuum lines.
  51. Install the right rear crossover pipe heat shield.
  52. Install the cables to the throttle body.
  53. Connect the fuel lines to the fuel rail and mount bracket.
  54. Install the inner fender electrical cover on the right side.
  55. Install the coolant recovery reservoir and upper radiator hose. Fill the cooling system.
  56. Install the air cleaner assembly and the fuel injector sight shield.
  57. Connect the negative battery cable.

Jan 31, 2011 | 1993 Buick Regal

1 Answer

The rubber o-rings fell out of the fuel line, and I need to know what order they are supposed to be in so I can put them back correctly.


emove the six reverse torx bolts from the fuel rail using an E7 star socket. You may notice that the paper fuel rail gasket is starting to or maybe already has broken between the intake ports. This will cause a lean code condition. (P0171 and P0174)
2. Gently pry the fuel rail off of the lower intake and the six injectors. Note the orientation of the injectors beforehand.
3. Remove all six injectors and discard all 12 o-rings.
4. Thoroughly clean all gasket surfaces and o-ring surfaces.
5. Clean the o-ring areas on all the injectors.
6. Put new o-rings on the injectors. A light film of motor oil on the o-rings will help in seating the injectors.
7. Put the injectors into the lower intake.
8. Put new paper gasket between the fuel rail and lower intake and make sure all of the injectors are seated into the fuel rail.
9. Put the six reverse torx bolts back in and torque them down in this sequence:
<Firewall 1 3 5
............ 6 4 2
To 12-16 N*m (9-11 lb*ft)

reassembly is the reverse of the dissassembly. after you get this done, get you a cold one. heck get two. you deserve it.

(you can let the children and small animals back in the area now)

Dec 06, 2010 | 1993 Ford Explorer Limited

2 Answers

WHERE IS NUMBER 6 FUEL INJECTOR LOCATED


The #6 fuel injector is located with the #6 cylinder and I have added a firing order and cylinder layout diagram that should help you out.


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Jun 11, 2010 | 1993 Toyota Camry V6

2 Answers

Can i replace a 3.0litres diesel turbo engine from a 2002 isuzu trooper with a 3.1litres diesel turbo engine.And if possible how can this be done?


Yes you can . Requires some skills but the only bits that dont work after are the speedo and the rev counter .

These can be made to work but its a bit tricky ..

Jan 26, 2010 | 2002 Isuzu Trooper

1 Answer

Truck cuts off when put in gear


If its the 4JX diesel engine the crankshaft position sensor wants an adjustment as its going out of range.

Apr 19, 2009 | 2002 Isuzu Trooper

2 Answers

02 Trooper intermittenly dies on idle.


This maybe due to an intake gasket leaking vacuum and causing a lean air-fuel mixture. Check for a vacuum leak where the lower intake plenum meets the cylinder heads. Separating the upper and lower intake manifold is not necessary. These gaskets are plastic and metal. The plastic gasket cracks causing a vacuum leak. This is an unmetered air leak and may cause fuel trim codes like PO171 and Po174 to set. There is an updated gaskets to repair the problem from Isuzu. These codes are for a lean fuel condition, not bad O2 sensors. Do you also have a rough idle?

Jan 25, 2009 | 2002 Isuzu Trooper

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