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Discussion Starter #1 (Edited)
So I had the Injen Short Ram Intake fitted to my Fiesta ST yesterday, this one - http://www.injen-europe.com/ford/fiesta-1-6l-4-cyl-short-ram-air-intake-system.html

Instant loss of power (my ass tells me 30bhp), doesn't feel to be boosting as much. Anyway, the weirdest thing happens, about 70 miles later and 2 drive cycles I'm pulling away from some lights and I think "oh what, this feels a bit sharper" ... Throttle is more responsive, can hear it sucking in, the famous TSSS noise is sharper and faster rather than a longer quieter tssssssss and most of all she seems about 15bhp (again, my ass telling me, no dyno) gain over stock, so I'm enjoying the extra power and all noises that came with (the spool, the suction, the TSSS) then a orange spanner light and a warning "Engine Malfunction, Service Now" and limp mode but when I turn the car off and on, I have the power back and running faster than stock for all of 30-60 seconds until the warning comes back, car off and on and she's fine, then it comes back...

I had a code reader on her today and the technician didn't write the code down for me :mad: he told me that there was a MAF sensor fault but he cleared it and now I'm back at the start with my ass telling me there is a 30bhp loss and also my ears telling me there's not as much boost as there was with the stock intake.

Any ideas?

Dan.
 

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If it's an oiled filter, your MAF could be dirty
 

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I agree. I would bet you dirtied or damaged the maf and it takes some period of time to identify that there is an issue before it goes to limp. Maf values being wrong could obviously cost you power.
 

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Discussion Starter #5 (Edited)
Yeah it's an oiled filter, seems you guys replying at the same time with the same thing about the MAF (dirty or damaged) are probably right. What should I do, stick the stock intake on for a while and see if she goes limp again as I can't take it in to Ford with the Injen (even though I work at a Ford dealership, they won't help me out while it's fitted)

I'd check turbo connection for loose fitment


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Even though when it goes limp all I do is turn the car off and on and all power is restored. I think it is sensor related.

I have a 3" decat waiting to go on but I need to figure this out first ;)
 

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If I were you I'd check the turbo fitment. If it's loose you could over boost badly and blow your turbo


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Yeah, a loose fitting connection could also definitely cause it... your turbo will be sucking in more air than your MAF sees.
 

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Discussion Starter #8 (Edited)
Ok here is an update.

Checked all connections/fittings, cleaned MAF, reset codes, went for a drive.

Power was sluggish, it wasn't a collapsing boost hose but that was the feeling and best way to describe what was happening, so around 30-40BHP loss.

3 drive cycles of 3-5 motorway miles, brings up the fault code, the code reader was plugged in while driving and it was saying "pending fault code" and actually shown it on the 3rd drive cycle and gave the famous "Engine Malfunction, Service Now" spanner on dash and limp mode.
Car off and on, code is still showing on the Snap-On code reader (latest software for 2014) but the car/ecu/maf has learned the new parameters for the extra air and is utilizing it, extra low end power, sounds more open (less restrictive), better throttle response, sounds totally awesome then throws the car back in to limp mode. Turn the car off and on, back to all the glory of the intake until limp mode again, this will go on forever, drove the car 2 days like this and went limp 30+ times.

Now I am no tech like the guy working on the car for me but in my mind I was thinking "I bet the software is locked and can't learn the new parameters" - turns out this is probably right, tried to reset parameters and the Snap-On code reader said something along the lines of - "this will reset MAF/ECU [can't remember what it said exactly] and the car will learn the new parameters, the car may drive different for a short period of time while it learns" - next next yes yes ok ok, "failed to reset, software locked". Right there, that's the problem, the car learns the new air coming in but can't store the parameters (temperature, airflow, etc etc...)

Tech fits the stock intake, resets codes, car drives fine, like stock (though I miss the extra low end power and throttle response *sad face*). The reason he fit the stock one back because we assumed the MAF might of been damaged or gotten dirty during INJEN install, turned out to be fine.

This got me wondering why only 1/100 people who fit a new intake run in to this problem (I've seen some other threads about the same issue)... There are two options, unlock Ford software (god knows how) so the MAF/ECU can learn the new parameters or get a remap (which isn't next on my list as I have a decat to fit, intercooler and pipes to buy and fit then a remap).

Now, why can some people fit an intake without the need of a remap and have no issues, I'm thinking that is because I have the latest update (I think there have been 3 since September 2013) and that in one of these updates they locked the software, people with older software are unlocked and the ECU can learn the new parameters.

Sorry I dragged this out but I wanted to get all my thoughts in here.

Dan.
 

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that's a really weird order to go in for your remap upgrades

In case you weren't already aware, that decat downpipe will cause a CEL code. No way around it.
FMIC + Pipes will help but without remap they won't do much.

Ken at Mountune will tell you the same - to get the most out of your hard parts you'll need a tune to match.

Not sure why you got a CEL - I ran my Injen after I got my Cobb unit but never had issues.
Straight away, somethings up with your MAF and the car isn't running right.

I felt a little power loss with the Injen when it got real hot underhood (given that you don't have an AP you can't monitor IAT and charge air temp so we're going to have to guess) but most of the time the power of it was snappier.
Gotta be something wrong.

Important question. Is your Fiesta ST US or Euro spec?
 

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Is this a 3 door car and if so it is MAF tuned ?
 
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Discussion Starter #11 (Edited)
that's a really weird order to go in for your remap upgrades

In case you weren't already aware, that decat downpipe will cause a CEL code. No way around it.
FMIC + Pipes will help but without remap they won't do much.

Ken at Mountune will tell you the same - to get the most out of your hard parts you'll need a tune to match.

Not sure why you got a CEL - I ran my Injen after I got my Cobb unit but never had issues.
Straight away, somethings up with your MAF and the car isn't running right.

I felt a little power loss with the Injen when it got real hot underhood (given that you don't have an AP you can't monitor IAT and charge air temp so we're going to have to guess) but most of the time the power of it was snappier.
Gotta be something wrong.

Important question. Is your Fiesta ST US or Euro spec?
Forgive me if I wasn't clear but that's what I said. I want to fit the hardware then remap the car, but I can't remap it for another 6 weeks and can't deal with limp mode for 6 weeks with the Injen fitted. The car is Euro, I monitored intake temps, between 8 and 11c above ambient. As for the CEL from the decat, stage 2 map will fix that, maybe a O2 / lambda spacer will keep the light off until then.


Is this a 3 door car and if so it is MAF tuned ?
3door yes, and what do you mean by maf tuned? If you mean so the car knows the new airflow and such... I can't reset the variables for it to learn the new air flow as the software is locked by Ford.
 

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the US (5dr) and EU/AUS (3dr) are tuned differently (hence why he asks i suppose)
Correct the NA cars are what they call speed density tunes not using the MAF to correctly set the air/fuel ratio as the EU and ROW (rest of world 3 door cars) So anything I have to offer is not useful for you .. Hmmmm
 

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Something I noticed on the Injen as apposed to my intake hose/ Sri combo (JS performance) and the stock system is that the bleeder tube from the FMIC/EVAP pipes in before the MAF sensor.
This might not effect NA cars but could it throw off our MAF tuned cars? Just spitballin here.


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Discussion Starter #15
Ah man, I have no idea what to do. I explained my problems to a guy at Revo just now and he is "pretty sure" they will get around the issue when they remap it. He said they have had 2 others in that one shop with the same issue (with Injen intake), I made him aware that I'd be arriving in limp mode and again, he should it "should be ok" ... It's just a lot of money to waste if things don't go ok :/
 

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What Mofist has said looks like it could make a difference. It has a pipe feeding back into the injen intake before the MAF which when on a normal setup would be feeding in behind the MAF. This may cause issues on the Rest of the World cars that are maf tuned where as the NA ones wont notice this issue.
 

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As Injen develops in CA, I bet it is not designed for factory MAF tuning.

This is the same reason the tuning options are limited.

A lot of different variables to check.
 

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Something I noticed on the injen as apposed to my intake hose/ Sri combo (JS performance) and the stock system is that the bleeder tube from the FMIC/EVAP pipes in before the MAF sensor. This might not effect NA cars but could it through off our MAF tuned cars? Just spitballin here.


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Good pick up MO, this will Definitely cause a problem because the air that was bleed off through that bleed pipe in a close loop is now being "metered" twice.
 

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Discussion Starter #19 (Edited)
Would a stage 2 remap fix the problem (was thinking Revo)? A company had offered the Airtec intercooler, AS Performance Intake, with fitting plus fitting of a decat I already own and a stage 2 remap for £1075. If stage 2 map works with the Injen that would be amazing, rather have a full aluminum pipe to the turbo that I've already paid for, rather than paying £150 for a filter and 5" long piece of metal for the MAF.

I honesty can not justify £150 for this when I paid £140 (yeah I know, it doesn't work) for aluminum straight to the turbo Auto Specialists - Stage 2 AS Performance ST 1.6 Eco Boost - free flowing induction kit

And look at that dyno, with the injen fitted you see how soon you get power, when I had it on and it would work for a few minutes before limp mode it was an odd feeling to say the least, where I'm normally waiting for boost, power was there waiting with the throttle being mad responsive. http://blog.modbargains.com/wp-content/uploads/2014/02/Fiesta_ST-Injen-Intake-Dyno001.jpg
 
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