I've got his tunes on two cars and loaded them for quite a few others, yours is the first with emission issues

 

In Texas every car has to be inspected every year, and you cannot register the car without a passing annual inspection. Are you certain that all those cars: 1) require emissions testing; 2) those tune installations are at least a year old and their inspections have expired and the owners have re-inspected the vehicles?

 

Followup: Case in point, only 20 out of 100 counties in North Carolina require emissions testing during the annual inspection, therefore 80% of NC counties only require a safety inspection.

 

MrBlah, one other question while trying to pin this problem down: When Adrian tuned my pre-facelift 2004 we switched the ECU to a post-facelift MS5150 ECU at the same time. Have either of your tuned Minis, or others you've facilitated tunes for, switched ECU types? Thanks.

 

all of them are facelift ecu's with adrian's modifications

 

... in counties that require emissions testing?

 

yes

 

Trying to eliminate all possibilities here: Are you aware of any that have passed emissions testing during an annual state inspection? Were they facelift ECUs installed in non-facelift Minis?