(T) JTD/MJET - induction and remaps, please read!

Folks I need some help (ok ok, not that kind ) as I'm trying to get to the bottom of a fault which seems to be on most (but not all) JTD Stilos that have been remapped at Red Dot..... and I'm looking for the impossible..... perhaps. Anyway, please read on:

If you have a JTD or MJET and have had the GSR induction kit fitted but have not had a remap done please post something and I'll be in touch.

Or..... have you had the Red Dot Racing remap done but have not had the GSR induction kit fitted please post something and again, I'll be in touch.

Also! Have you had your Stilo remapped elsewhere..... and have a different induction kit or the standard set up on your car? Again please post something.

I have one or two pet theories about why the 'engine fault' alarm comes up on many JTD/MJET that have been remapped/induction kits fitted and as it irritates the hell out of me I'm determined to find the cause of the problem and see it gone..... so I'm trying to pick my way through as much information as I can get from fellow diesel burners who've had their cars 'tweaked'. To play around with a famous phrase from Mr Holmes:
"It is an old maxim of mine that when you have excluded the possible and the obvious, whatever remains, however improbable or annoying , must be the cause".

Hopefully, if this topic is well replied to and folk are honest about what's going on with their cars, we will once and for all be able to figure out an answer to the engine fault spies. So please do contribute

04 JTD, remapped by Angel, no induction kit. Engine fault occures irregularly with P0235 code.

These errors appeared before the remap also.

02 JTD, remapped by Angel, no induction kit.

Errors reported: NONE

Any power drop off at the same time.... or just a quick alarm?

Really..... have you changed the MAF at all

Now im no tech but it would seem that this problem is mainly to do with changing the air flow. Perhaps a sudden difference to what the ECU is expecting over a period of time is confusing it as it tries to adjust to the new readings.
This problem is not just restricted to the Stilo JTD but similar anomalies i personally have notices in Punto MK2 Sporting and my current Stilo.
Like i think you said this is not a problem srecific to Red Dot and GSR but rather the Ecu.
The MK2 Sporting experiences erratic electrical behaviour after the fitting of and induction kit from Lambda sensors “Failing” to the Sparkplugs quickly smutting up and being rendered useless.
Have you researched into weather this is restricted to just fiat or have modern non Racing Ecu's got just too complex to handle these kind of changes.

Abz,
As you are aware from our posts on Performance Stilo i have the Reddot Map with standard induction and experience the engine fault with no noticable drop in power. I have found that it is better (ie less often) of i turn ASR off. Now i know they are probably unrelated but i think it has made a difference. I also prefer the feel of the brakes with ASR off.

Volxstu,
the fault Abz is talking about is in relation to overboost pressure, so this one is just for the JTD/MJET because of the Turbo.

Yes, power drops off i.e no turbo.

Had a MAF changed just after I got the car, not changed since but as I say, happened pre and post re-map.

You're getting to where I am at the moment...... part of the answer may be to 'cheat' the sensors over the ECU. Personally I suspect the sensors are most probably the significant factor.

Obviously the best answer is a fully mapped system which is well away from the limitations of anything OE. However, I have researched a few other cars (eg. Fabia VRs) and without exception (so far) few similar problems reported

Mini...... I don't have ASR so can't comment

I do have an idea of how to make the 'spies' go away...... hopefully sooner rather than later. We will see! As I've had no help from other fronts to resolve the faults it seems sensible to me to have a go rather than make do

Come on folks - more posts please. All info is good

In which gears - 3rd/4th/5th? Perhaps around 2500-3000 rpm ? (aka: "the sweet spot" ).

In 1st, just as I am rolling up to lights usually at about 1K revs. No revs at all, almost tickover. Never had a problem under load.

Now that is very interesting - nothing ever under load

Apart from when the intercooler hose split but that's a fault that might not form part of any investigation you are conducting.

Quite right - it's not what I'm looking at, although intercooler performance is something that has been suggested I look into on 'tweaked' engines

angel remap gave me p0235 error code. Always under load between 2500-3000rpm. Then chipped uk was the same but not as bad and that was with gsr induction. Very big improvement when i changed maf sensor. No improvement after replacing egr or overboost valve.

Have you tried cleaning your inlet manifold and stop valve. It is quite a job to get the manifold off, but they really get gummed up with the EGR soot mixed with oil and the airflow is significantly restricted into the engine. I have cleaned the stop/ air cutoff valve on mine, but have not tried the manifold yet. (Mine is not remapped and I don't get error codes) but think it is something you should try. Also clean the MAP sensor at the same time.