john in KY

Been my experience that removing that beveled washer really helps in axle removal.

I have a good 4EAT I saved from an 89 XT6 I recently parted. John

http://louisville.craigslist.org/pts/1051023076.html Don't know if the seller still has it but if so, within a day's drive.

Brat Dog nailed the problem. Somehow you pulled a plug loose or pulled a wire loose from a plug. Bunch of wires behind the kick panel also.

I have an XT6 ignition sw/key if you decide to go that route.

Coil pack.

No pressure when the radiator cap was removed suggests the system either has a hole somewhere or the cap is junk. No pressure means the coolant will boil at a lower temperature. I'd replace the cap first.

Sounds a lot like the coil pack is beginning to fail. The next time the engine starts to miss, take a close look at the coil pack. Bet you see arcing to the intake manifold.

Still believe it is the control unit or just maybe the control unit has lost its main power supply. The control unit circuit I have to believe has to have a fuse somewhere in the circuit. May want to explore that. I have an extra control unit from an XT6, Have no idea if it is the same used in your model.

Has to be at the pump. When a strut is inflated, the air line between the strut and its solenoid is also pressurized. When the solenoid opens and the pump is not running, the pressurized air can only flow back to the pump where it is dumped. I'm assuming here both front struts went flat. Can't believe both struts or both front solenoids failed simultaneously. My guess is the problem is that control unit under the carpet.

All 4 solenoids open with a 12 volt signal. If you have 12 volts then the solenoid is bad or the ground. No 12 volts then think the control unit may be bad. Including a photo of the control unit for an XT6. Located under the carpet between the front seat and door. Probably in the same location for your car. May be worth the trouble to insure it is grounded. Have seen a few where the ground was corroded causing all sorts of problems. Hard to believe an air leak is the problem. System isn't all that complicated. When a strut is low, a signal is sent to the control unit. Control unit sends a signal to that solenoid which opens and air from the tank flows to the low strut. Tank pressure gets too low then another signal is sent to the compressor and it restores pressure.

Pull the fuel line at the pump that feeds the pump. Every time I have done this fuel flows freely. If you don't get a flow then there is a problem with the line between the pump and tank. Don't think replacing the FPR will do anything.

Why not just replace the engine with another ER27?

The XT and XT6 inner bushing are different. You could enlarge the bolt hole in the engine cradle but the other problem is the ball joint. Also different.

Time for a new radiator.

If turboed than 3.70. The FWD turbos came with a 3.54.

I may have a new 2-row XT radiator. Bought it awhile back because I was told it was for the XT6. Once I opened the box and measured the inlet and outlet, I knew it was for the XT. Never fooled with it after that. Pm me if you want a photo/price. John

Could be wrong here but seem to recall the valve cover bolts are "stepped". If so, they can't be overtorqued.

See if you can determine if this is one of those many "hurricane" cars.

Had this problem once after doing a tune up. A miss only at idle. Eventually discovered I had cracked a small vacuum line on the manifold when I guess I was replacing the plug wires. Check the lines over on the passenger side.

I'd pop in a new radiator along with the hoses. Could save you a lot of future problems.

Red turbo/downpipe to me indicates excessive fuel burning in the exhaust system. Any idea where the timing is set?

New fuel filter installed backwards?

I would suspect the coil pack as the problem.