Engine Failsafe Prog Solved

[ggj13557]

I have been posting/reviewing this forum for several days now about a "Engine Failsafe Prog" dashboard error. I have received several helpful hints as to what the problem may be, all of which I eventually ran to ground.

I have a 2002 BMW X5 3.0

Problem:

I filled up with gas and got back on the road headed for home. I put cruise control on and as the car started to climb a slight incline the accelerator kicked in to maintain my speed. All of a sudden, the car started to buck and lose power. The brakes lost power and the accelerator was completely unresponsive! I limped the X5 into a parking lot and tried to replay everything that had just happened. I had lights all over my dash from DSC failure to Check Engine. The display was showing Trans Failsafe Prog and Engine Failsafe Prog. Since I couldn't drive the car I had to have it towed home. I searched the forum in search of an answer. It was very late Sunday night but SlickGT1 was responding with answers and things to try...Thank you! He suggested looking at the voltage, which I did. My voltage was around 11.8 with engine off and between 12.7 and 13.1 with engine idle very rough. I ordered a code reader and pulled the following codes three days later (work got in the way :-))

Here are the initial codes:

Code Description Retrieval Time
P1632 Smart Alternator Faults Sensor/Circuit Malfunction 2012-08-30 18:52:36
P1639 Vehicle ID Block Corrupted or Not Programmed 2012-08-30 18:52:36
P1638 Can Link ECM/INSTM Circuit / Network Malfunction 2012-08-30 18:52:36

I suspected the alternator and the battery. Turns out the battery was fine. I replaced the alternator. Same problem.

I pulled codes again. Now I was only getting one:

Code Description Retrieval Time
P1632 Throttle Valve Adaptation; Adaptation Condition Not Met (Pending) 2012-08-31 14:11:37

After some soul searching I decided to try my luck at the BMW dealership. The guys in the parts department here are awesome! After some research he suggested that I check the Throttle position sensor to see if carbon had collected to a point that the butterfly valve would not shut. I stopped and picked up some throttle body cleaner and begin disassembling again. As soon as I removed the large elbow hose leading from the MAF I found the source of the problem!

I large rubber gasket was caught in the butterfly valve and would not let it shut. I still don't know where this gasket came from...I'll figure that out later. I reassembled everything and it runs great!

Resolution:

The butterfly valve in the Throttle Housing Assembly was being held open by a large rubber gasket.

No. Description Supplement Qty From Up To Part Number Price Notes Photo
01 Throttle Housing Assy 1 13547502445 $362.72

This may be a unique situation but I ran across so many posts that sounded like the situation that I experienced yet there was no resolution.

This problem is solved.

[TerminatorX5]

Dennis is your man - he knows a lot sh!t!!!

[bastereo]

The rubber gasket is probably from the junction between your maf and intake tube.
It helps the 2 hard plastic pieces seal to each other.

[FITZUNI]

Great Job...

[gto88]

First of all, I'd like to thank ggj13557 for posting this issue and solution.
I had my 2001 x5 throttle body cleanup myself an hour ago, and after I was
done and assembled everything back, started the engine, and the problem showed.
The engine rmp jump up and down, car shaking, check engine light is on, and all
seem a disaster begun.

I search the web like crazy trying to find solution... after a few tries without
luck, I see this post, saying about something stuck the throttle body.
I recalled that when I wiped the throttle body with cleaner I tore off a few piece
of workshop paper (blue color from auto part) inside, but I thought that I had it
removed.
With a strong hope and pray for help.
I redo everything from beginning again, and luckily I found a piece of paper stuck at the throttle body, I had to use mirror to see it inside since the throttle body of X5 is kind of lower inside.
After removed the paper and made sure the butterfly value is freely close and open and assembled everything, the engine starts fine.

Really thanks for the tip.

[kado1976]

[QUOTE
I large rubber gasket was caught in the butterfly valve and would not let it shut. I still don't know where this gasket came from...I'll figure that out later. I reassembled everything and it runs great!

Resolution:

The butterfly valve in the Throttle Housing Assembly was being held open by a large rubber gasket.

This problem is solved.[/QUOTE]


Wow this happened to me this morning! I know the where the Gremlin came from in my case. unfortunately I was I5 when it happened so I had no choice but waste money on a tow. The culprit was myself. I replaced the HID bulbs and when I reinstalled the air cleaner box the gasket near the MAS gut wedged and eventually sucked into the throttle body. wasted $100 from a dumb mistake but Ill take that over a massive BMW bill anyday.

MAS is a big flag for program failsafe with rough idle and almost no gas pedal response.

Thanks wish I saw this thread before I took it to the shop.

[james520]

very good job

[DrRick]

Great Forum in general and a save my butt thread.
I was hauling A*S, moving through the gears, up to redline; suddenly the car just, kinda, dies. See above posts for details. Is what happened to me. Lucky I was able to coast into my driveway.

The first pic is taken with the intake plenum removed, looking down into throttle body plenum. The rest are self explanatory.
RickP

[X5Flyboy]

WOW! My 2001 X5 4,4 sport is presently at the dealership with this same "TRANS.FAILSAFE.PROG" error message. Mine occurred with only the error message and a disengagement of the driveshaft, ie I ended up coasting on the interstate. Fortunately traffic around me disappeared and I eased over to the side from the 3rd lane of 4 northbound lanes on I-15 in Salt Lake City.

In an hour, I plan to call them and suggest they check out what you have found in your situation. Only difference may be that I have a Dinan throttle body. So I'd like to know where the gasket came from?????

Thanks for sharing!

[upallnight]

Originally Posted by X5Flyboy

WOW! My 2001 X5 4,4 sport is presently at the dealership with this same "TRANS.FAILSAFE.PROG" error message. Mine occurred with only the error message and a disengagement of the driveshaft, ie I ended up coasting on the interstate. Fortunately traffic around me disappeared and I eased over to the side from the 3rd lane of 4 northbound lanes on I-15 in Salt Lake City.

In an hour, I plan to call them and suggest they check out what you have found in your situation. Only difference may be that I have a Dinan throttle body. So I'd like to know where the gasket came from?????

Thanks for sharing!

The gasket that peoples have posted is located between the MAF and the throttle body. Don't know if a V8 engine use a similar gasket or not. It's hard to install that gasket correctly since it has a tendency to roll under as you put the rubber bellow onto the gasket and MAF.