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#1 Old 11-14-2011, 11:34 AM
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More stalling issues!

2002 Hyundai Sonata 4cyl. About a month ago had a problem with vehicle stalling in drive at stops. Replaced IAC valve, cleaned the air intake manifold & had the fuel system cleaned. Seemed to have fixed the problem with car stalling at idle in drive. Now, the car has begun to randomly stall within 5-10 minutes of startup during a 1st to 2nd gear shift acceleration exceeding 2500 rpms. Examples of this has been accelerating from stop lights and slowing down and accelerating out of turns. The check engine light came on. There were 2 codes read: a IAC high rpm code and a crankshaft sensor malfunction. Recently took it to a private mechanic. They said they could replace the crankshaft sensor for $400, but they said that might not solve the problem. They also said it could be an ECU (engine control unit) in which case a certified Hyundai mechanic would need to determine the best course of action to fix it. I've taken this car to a privately owned mechanic shop and 2 Hyundai dealers with different opinions. The dealers were suggesting $800-$1000 amounts of work which they also said might not fix the problem. I don't want to just keep throwing money down the drain hoping the car is fixed on mechanics guesses. Has anyone experienced this or have any thoughts what could be causing this? Sorry for being long but this has been frustrating
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#2 Old 11-15-2011, 10:52 AM
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Originally Posted by jswick View Post
2002 Hyundai Sonata 4cyl. About a month ago had a problem with vehicle stalling in drive at stops. Replaced IAC valve, cleaned the air intake manifold & had the fuel system cleaned. Seemed to have fixed the problem with car stalling at idle in drive. Now, the car has begun to randomly stall within 5-10 minutes of startup during a 1st to 2nd gear shift acceleration exceeding 2500 rpms. Examples of this has been accelerating from stop lights and slowing down and accelerating out of turns. The check engine light came on. There were 2 codes read: a IAC high rpm code and a crankshaft sensor malfunction. Recently took it to a private mechanic. They said they could replace the crankshaft sensor for $400, but they said that might not solve the problem. They also said it could be an ECU (engine control unit) in which case a certified Hyundai mechanic would need to determine the best course of action to fix it. I've taken this car to a privately owned mechanic shop and 2 Hyundai dealers with different opinions. The dealers were suggesting $800-$1000 amounts of work which they also said might not fix the problem. I don't want to just keep throwing money down the drain hoping the car is fixed on mechanics guesses. Has anyone experienced this or have any thoughts what could be causing this? Sorry for being long but this has been frustrating
More than likely a Crankcase Position Sensor. If you had the 2.7, this would be a fairly easy fix, but the four cyl needs a lot of work to get to the CPS. Almost like changing out the timing belt. This is a good post to let people know to change out their CPS when they do their timing belt as a preventative maintenance issue(well worth the cost of a $70 sensor). I just changed out my CPS on my 03 Santa fe that had a jerking/bucking problem for several years, but it occasionally stalled at stop signs too. It fixed that problem for me and I've read many posts about stalls being a CPS.

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#3 Old 11-16-2011, 10:17 AM
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Thanks for the info. I took it to a Hyundai mechanic and he said the same thing. If it's a CPS for the 4 cyl., it's a pretty extensive job labor-wise. He recommended either having the timing belt tightened or replaced depending on it's condition since the sensor is in close proximity to the belt. Btw, my 02 Sonata has only 104k miles and I have taken good care of it with routine maintenance. So this could happen to others with older model Sonatas.
Now, I just have to wait for the check engine code to come back on before they can thoroughly diagnose it. The last mechanic I took the car to cleared the codes without being able to fix the problem!
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#4 Old 11-16-2011, 07:27 PM
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Thanks for the info. I took it to a Hyundai mechanic and he said the same thing. If it's a CPS for the 4 cyl., it's a pretty extensive job labor-wise. He recommended either having the timing belt tightened or replaced depending on it's condition since the sensor is in close proximity to the belt. Btw, my 02 Sonata has only 104k miles and I have taken good care of it with routine maintenance. So this could happen to others with older model Sonatas.
Now, I just have to wait for the check engine code to come back on before they can thoroughly diagnose it. The last mechanic I took the car to cleared the codes without being able to fix the problem!
In process of replacing 2.4 crank position sensor, started late today,,, finish in morning.. if you anywhere near coming up for timing belt... just replace it, along with the balance shaft belt, tensioner (DO NOT RECYCLE OLD PART), and 2 drive belts... be done with it the first time.
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#5 Old 12-07-2011, 03:28 PM
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Thought I'd share this. After doing some research and talking with a small town mechanic, the problem seemed to be in my replacement of the idle air control valve. When I purchased the iac and replaced it in my car, I did not install a gasket. The old iac had a thin o-ring type of gasket that was very flimsy and had broken in half. The new part did not come with a replacement gasket, and when I asked 2 Hyundai dealer mechanics, they said it wasn't necessary. It is! A mechanic from my wife's small town said that it certainly is necessary. Said that air can escape and cause the codes for vacuum loss and the car stalling/surging issues. I got a small 3x5 piece of gasket material from Autozone and rigged up a gasket by cutting it out in the shape of the iac valve. Once I installed this gasket, everything seemed to be working properly. So just remember that a gasket/seal of some kind is necessary when installing an iac valve! Thanks,
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#6 Old 12-07-2011, 09:29 PM
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jswick....
If I read it correctly you said "The TB "only" has 104k miles on it"
OMG...If that's true when it soon breaks you will have a MAJOR engine repair...
The TBs are to be replaced EVERY 60k miles and I have seen posts of them them failing often around 85k miles...
Just want to keep your Sontata running...
Dave
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#7 Old 12-08-2011, 07:28 AM
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Originally Posted by MyKids04Sonata View Post
jswick....
If I read it correctly you said "The TB "only" has 104k miles on it"
OMG...If that's true when it soon breaks you will have a MAJOR engine repair...
The TBs are to be replaced EVERY 60k miles and I have seen posts of them them failing often around 85k miles...
Just want to keep your Sontata running...
Dave
No, I've had the timing belt replaced at 65k, so it has about 40k on it. If I was going to get the crankshaft sensor replaced, it was recommended that I go ahead and get the timing belt replaced too since the sensor is in close proximity to the belt. Killing two birds with one stone so to speak. But, the last mechanic could find no previous crankshaft codes, so it wasn't necessary. Just needed the gasket on the iac valve to operate normally.
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