Seat Ibiza FR gets treated to custom remap and a Milltek System

Seat Ibiza FR Milltek, custom  remap, ade tuning

After owning his 1.8 20v Seat Ibiza for several months, our customer decided to improve the car with a Milltek Sport system and a custom remap. After getting in touch with us via our Facebook page we priced up the different options available for his car and sent him the details. The next day he came down to pay for his exhaust system and book in for the fitting and a custom remap to suit. Our customer chose the Milltek decat with the non resonated oval tailpipe – awesome choice!

milltek sports, ade tuning, ibiza frMilltek Exhausts Lancashire

Exhaust and Remap Day

The day final arrived when the Seat Ibiza FR would be dropped off for it’s new exhaust to be fitted and then for it to be custom remapped 🙂
The owner of the Ibiza had already made some performance modifications before bring the car to us. These include a front mounted intercooler, TIP (throttle intake pipe), diverter valve and a good quality panel filter.

With the car on the ramp it was time to start taking the old exhaust system off the car and fitting the shiny new Milltek Sport decat exhaust system.
milltek, ade tuning, seat ibiza fr
milltek, ade tuning, seat ibiza fr

milltek, ade tuning, seat ibiza fr

With the exhaust fitted and tested for any leaks it was then over to the rolling road for the custom remap. Standard power for the Seat Ibiza FR is 147BHP as standard so we expected some good results from this car. With custom remap written and the car tested on the dyno and the road we handed it back over to its proud owner for their test drive.


Really happy with the work done to my Ibiza, the Milltek Exhaust sounds nuts and the custom remap has turned the car into a bit of an animal. The quality of the tune the car received is second to none, the driveability is noticeably better in all situations – Highly Recommended. Top work guys!


VW Passat inlet manifold issue

vw passat inlet manifold swirl flaps ade tuning

The inlet manifold is part of the engine that supplies the air/fuel mixture in to the cylinder. The primary function of the intake manifold is to evenly distribute the combustion mixture (or just air in a direct injection engine) to each intake port in the cylinder head(s). Even distribution is important to optimize the efficiency and performance of the engine.

The inlet manifold contains Swirl flaps, which are small butterfly valves fitted to the intake manifold. These are just before the cylinder head intake ports. They are fitted in many modern automotive diesel engines, including those from Audi, BMW, Vauxhall and Alfa Romeo. The flaps are smaller than the intake runners. Therefore allow air to pass around them even when “closed”. Swirl flap position is adjusted by an electrical or vacuum-activated servo mechanism which is under the control of the engine management system. In a typical implementation the flaps will be closed at idle speed, creating additional turbulence in the intake.

So What Does The Intake Do?

As engine speed increases, the flaps are gradually opened until, at around 2,000 rpm, they are parallel to the airflow and present virtually no resistance. Their purpose is to ensure that the air entering the cylinder is sufficiently turbulent for good fuel-air mixing even at low engine speeds. The disadvantages of swirl flaps are mainly associated with fouling by exhaust gas recirculation. This leaves tarry deposits on the flaps and the inside of the intake manifold. Over time the flaps can begin to stick in one position. The engine management system may report an error code if the correct flap position cannot be achieved within a few percent of the design specification.

More seriously, the flaps or their mountings can fracture under the strain and parts can enter the cylinder. This almost always causes major engine damage due to the very small clearances inside a diesel engine. Some owners choose to have the flaps removed as a precaution, with blanking plates fitted to maintain manifold sealing. In many cases the impact on driveability and fuel economy is negligible.

ade tuning vw inlet manifold

Swirl Flaps

The Passat owner came to the workshop as his car was running badly and the engine management light illuminated on the dash. We plugged the car into the diagnostic machine and it came up with a code which we recognized immediately. The fault was for the Intake Manifold Flap Position Sensor. This sensor is only available with the whole intake manifold – a very expensive job. But we have experienced this issue before and knew that if we were able to source an earlier model inlet manifold (a non-flap inlet manifold) we would be able to blank the swirl flaps and seal the manifold completely.

Inside The Inlet Manifold

When we removed the inlet manifold we could easily see what had happened. The swirl flap in the first manifold hole had snapped causing the flap rail to vibrate sideways. This eventually caused a hole to appear at the far end of the flap rail which had led to a boost leak. We where very lucky to catch it at this stage as the worst case scenario would be engine damage.

inlet manifold swirl flaps ade tuning

ECU Remap

With the engine built back up with the non swirl flapped inlet manifold in position we ran the car to check there where still no boost leaks. Then we reprogrammed the ecu so the car would run without the original inlet manifold on.

Unfortunately when you look more into this problem it isn’t just the VW Passat that has issues with swirl flaps and the inlet manifold. The problem also affects Audi, BMW, Vauxhall and Alfa Romeo.

Blyton Park Track Day August 2015


Blyton Park

Back in August we attended at track day at Blyton Park near Gainsborough in Lincolnshire. Blyton Park offers a fun and challenging 1.6 mile track day circuit. The new high grip surface has excellent run off and is therefore ideal for beginners where as the more technical layout of the Eastern Circuit is more suited to an experienced driver or rider.

blyton park track day ade tuning

Our track day was organised through Javelin and we took the orange VW MK1 Golf out on the track. After the drivers briefing we went out for a sighting lap to allow you to become familiar with the layout of the track. It was a gloriously hot day and there was plenty of tasty cars out on the track.

Have a browse through some of the photographs we got on the day.


CNC Heads Championship racing at Oulton Park

ade tuning cnc heads honda type r

This weekend our head technician, Chris was competing in the CNC Heads sports and saloon championship down at Oulton Park. It’s not the first time that Chris has raced in this championship and last time he brought home a trophy for coming first in his class in his mk3 Ford Escort. This time he was competing in a Honda Civic Type R which his very kind friend Gareth had leant him. In the few weeks leading up to the race many hours where spent getting the Honda race spec ready. The Civic was even treated to a polish by Rachael, who claims that she increased the bhp by at least 10bhp 😉

Chris qualified 3rd in his class of 7 with most cars having a decent power edge on him.

In the first race he finished in 3rd even though he was locking up in every braking zone due to us taking the ABS out.

In his second race he started in 4th position, soon making his way into 3rd position and into a battle with 2nd place. It was looking like he was going to take the place, when unfortunately with about 3 laps to go the front 2 tyres de-laminated and left him unable to fight for position. Leaving him lame horse to the guys behind and he finished the race in 5th position.

ADE Tuning CNC Heads Honda Civic Type R

Rolling Road Days

Rolling Road Events

Rolling road day banner

As show season is slowly coming to an end it can only mean one thing … Rolling Road Days at ADE Tuning!

We can help you to organise and promote a Rolling Road event for either a group of your friends or a car club you are involved in.

We are fully equipped with our in-house 1200bhp 2wd dyno with a viewing area and large screen to watch the results as they happen and we have ample parking for all your cars and we are within 5 minutes drive from the M65.

Every car that runs on the dyno will receive a dyno print out of their results.

And with dyno runs starting from as little as £30 per car, you would be mad not to get in contact and see what we can do for you!

ade tuning dyno rolling road

ade tuning dyno rolling road