[Aldergrove]

Does anyone know the value of the gap for the CPS. Prior to reading this thread I asked a transmission tech who suggested .040`` which is considerably larger than Johns 1/64`` or .016``

Also, the crank sensor is very sensitive to the mounting depth. There should have been a space on a new sensor to set the proper gap. Improper gap will keep it from starting.

 

[Aldergrove]

I never knew that the connector behind the HVAC controls or a bad solder joint in the instrument panel cluster would cause a no start!!!!

Check for bad solder joints in the cluster, and/or a melted connector behind the HVAC controls.

These are two very common problem areas with these vans, especially as they get older, and will cause intermittent no start conditions like this (among other things). It's gotten to the point I would look at these two areas first, regardless of the codes being thrown.

Also, check to see if the PCM connector can be wiggled back and forth. If so, it's loose. Sometimes the bolts that hold the connector together are too long, and won't allow a secure connection even when tight. Cut a little bit off the end of the bolt if yours is loose. I successfully fixed a similar issue on my 1991 Fifth parts car this way. It threw constant crank sensor codes, but replacing it did not fix the problem. It was the PCM connector being loose that caused it.

Check for the cluster and HVAC issues for sure, though.

 

[Aldergrove]

If it is crucial to know the actual thickness of Chrysler's paper shim, you can contact a piano technician or a piano supply warehouse who will sell you dozens or give you a shim. In piano service, the keyboard height is regulated by adding or subtracting paper punchings. Consistant Precision and unifrom tolerances are required in setting up grand piano and upright piano keyboards enabling advanced pianistic skill to be expressed There are a large variety of sizes available ,so knowing the exact thickness can get you the a perfect replacement.

I've stacked a half a dozzen post-it notes and cut about a 3/8 X 3/8 sq in (cut on the sticky side). If the sensor is clean this will stick long enough to set the sensor in and tighten it up.

Nice to know you can buy the spacer at AAP and I hope they give you a few in the package for that price.