Engine Failsafe Program 2002 540i/6 w/ INPA Datalog

[Iamthebull]

Hi folks. Short version my 2002 540i/6 stopped running at a stoplight and have the Engine Failsafe Program error come up on the dash. Try to restart the car and I get a fast rev from about 800-1400 RPM and no power. I try again, same thing. Push the car through the intersection with the help of some bystanders to a parking lot. No weird burnt smells of any kind that I could notice, as I have seen sometimes happen with others that get this error. I tried starting the car again for good measure and thankfully it started, seemed to run fine and got home safely.

Go to start the car again and slightly different problem. Fast revs and dies. No Engine Failsafe Program.

I used INPA to get the error log which I have uploaded and attached as a .txt file. Had to convert from German, but it looks like it translated properly.

I'll be the first to state that I'm not sure what certain values should read, but I hope you all can help me in identifying what the readout says, and possibly what to start looking at.

I appreciate everyone's help with this in advance.

Oh and no recent changes, modifications, etc. I have had Dima's tune since 2019 with no issues.

540i INPA Errorlog.txt

[CPHES]

Can’t see the log ( mobile app view ). How’s the battery?

[Iamthebull]

Can’t see the log ( mobile app view ). How’s the battery?

Sorry about that, it should be there now.

[Iamthebull]

Can’t see the log ( mobile app view ). How’s the battery?

It "seems" fine. What voltage should it read?

[CPHES]

If it is weak, you can get trans fail safe get it fully charged, and tested. Let us know

[Iamthebull]

If it is weak, you can get trans fail safe get it fully charged, and tested. Let us know

Mines a manual, I'm getting the Engine Failsafe Program error, not the Trans Failsafe error.

[TiesTorN]

battery has nothing to do with it.

your throttle body is probably the culprit.

[Iamthebull]

Should I disconnect the throttle body cable and see if there's a difference?

[Iamthebull]

I disconnected the throttle body cable, starts, revs up to about 1800-2000 and then dies.

[TiesTorN]

I had the same symptoms and similar error codes last year, replacing TB solved it for me.

[Chedley]

So, the INPA error log in OP's first posting shows:
Supply voltage 10.93 volts for error 140 (thermostat)
Supply voltage 11.96 volts for error 130 (throttle DK)

1. That is a low or bad battery / alternator. Recharge the battery, and test the alternator. One should see a voltage of at least +12.4 volts with engine off, and +13.5 Volts with engine warm running.

2. Clean up the electric connections to the thermostat and the throttle. Reset the adaptations (engine off, key position 2, wait 35 seconds, remove key).

Erase all INPA errors, test drive , then scan again and report back.

[Iamthebull]

So, the INPA error log in OP's first posting shows:
Supply voltage 10.93 volts for error 140 (thermostat)
Supply voltage 11.96 volts for error 130 (throttle DK)

1. That is a low or bad battery / alternator. Recharge the battery, and test the alternator. One should see a voltage of at least +12.4 volts with engine off, and +13.5 Volts with engine warm running.

2. Clean up the electric connections to the thermostat and the throttle. Reset the adaptations (engine off, key position 2, wait 35 seconds, remove key).

Erase all INPA errors, test drive , then scan again and report back.

Thanks! I'll work on that tomorrow and let you know. Much appreciated.

[capebmw]

I second everything that Chad says. You really need to confirm that the electrical system is operating 100%, i.e. the battery, alternator, main connections. Start there before firing the parts cannon at it.

[Dking078]

Sounds more like TB failure, BUT also pull your DME and check plug 3 for signs of coolant/oil contamination. Yes, the DME plugs.

[Iamthebull]

Update: After having the car on a trickle charger all day, cleared the adaptations, car started and ran. Had power. I haven't checked the voltages with INPA yet. I'll check that in the morning, but it's looking like it might be a dying battery, but I don't entirely want to jump to conclusions yet.

Additionally I got the Engine Program Failsafe message upon initial start and shut down, but didn't pop up after second start. I'll be checking everything in INPA tomorrow.

[Iamthebull]

Update: I was out driving around and gave a good romp in 1st through second, Check Engine came on and was down on power wanting to die. I limped it home and when I went to start again I got the Engine Failsafe Program error again and immediately died after trying to start. I disconnected the battery for a few minutes, was able to start it run again. Hooked up INPA, have a couple screenshots. How are my voltages looking? I do receive a thermostat error, so I'm assuming I should replace this, but I don't want to presume before getting another opinion.

Edit: Had to convert the image files. Pics are on the post below.

[Iamthebull]

erroranalog010823.jpgErrorLog010823.png

[TiesTorN]

voltage is ok

it was corrected temporarily because clearing adaptations also resets the TB. I was gonna tell you that you'll have the same error very soon but I didn't wanna interfere too much lol.

your low voltage readings in the txt logs mean nothing because alternator starts working after a few seconds (to reduce drag on starter motor), until that the car basically runs of the battery.

I'm not gonna say 100%, but 99% chance your TB is bad.

[Chedley]

The tsat error happened with a pretty much emtty battery (11.02 volts). Low voltages. Save yourself money and headaches and unnecessary parts....
Replace the battery. Then test again. How old is this battery anyway ?

[Iamthebull]

voltage is ok

it was corrected temporarily because clearing adaptations also resets the TB. I was gonna tell you that you'll have the same error very soon but I didn't wanna interfere too much lol.

your low voltage readings in the txt logs mean nothing because alternator starts working after a few seconds (to reduce drag on starter motor), until that the car basically runs of the battery.

I'm not gonna say 100%, but 99% chance your TB is bad.

Thank you for the response. I do have an OEM N62 throttle body installed. I think I still have my stock throttle body in a box somewhere.

My question is why would a faulty throttle body cause this issue when it goes away after clearing the adaptations?

[TiesTorN]

Thank you for the response. I do have an OEM N62 throttle body installed. I think I still have my stock throttle body in a box somewhere.

My question is why would a faulty throttle body cause this issue when it goes away after clearing the adaptations?

there is a rheostat inside the tb that usually goes bad. dme gets the tb opening percentage info by reading the resistance value of rheosta. when a part of it goes bad, dme gets confused as u continue using it and throws errors like you are having.

[Iamthebull]

Good to know! I'll swap my stock TB back in and see what happens.

[Iamthebull]

Well. Turns out I tossed the TB or left it in California when I moved back to Missouri. Whoops. Off to the pick n pull tomorrow.

[Chedley]

Well, you may have a problem with the TB, but I strongly doubt it---.
Fact is the voltages INPA read in your error report above (11.02 v, and 11.87 v) are very low -whether the engine is on or off.
You have a bad or old battery that does not hold the charge. Replace it.

Then turn to the TB thing.

[Iamthebull]

Well, you may have a problem with the TB, but I strongly doubt it---.
Fact is the voltages INPA read in your error report above (11.02 v, and 11.87 v) are very low -whether the engine is on or off.
You have a bad or old battery that does not hold the charge. Replace it.

Then turn to the TB thing.

I do have a brand new battery that I just picked up for my dad's spare 528i that has some kind of separate electronic issue. I haven't hooked it up yet. I'll do that before getting another TB. Thanks guys.