High EGR failure rates create aftermarket opportunity
Certain engine components are particularly problematic for the aftermarket – chief among them is the exhaust gas recirculation (EGR) valve, according to Nissens Head of Marketing, Group Content Director, Jan Zieleskiewicz. For professionals working with diesel applications, especially those from VAG and PSA, the high failure rate of these parts poses both a technical challenge and a commercial opportunity.
The EGR valves used in more than seven million European VAG diesel vehicles, spanning 1.4, 1.6 and 2.0L TDI engines, are prone to failure. Heat, vibration and soot build-up combine to create harsh operating conditions, exacerbated by design limitations. In practice, this means faults can reappear – even when a part has already been replaced, frustrating technicians and motorists alike.
However, aftermarket manufacturers, like Nissens, are increasingly stepping in with solutions. By identifying the core weaknesses in original parts and applying targeted design improvements, these new units aim to deliver a longer-lasting alternative. For you, this represents a valuable talking point: not just selling a replacement but offering a durable fix – especially in applications with known fault histories.
From the workshop perspective, reliability and ease of fitment remain paramount. A ‘first-time fit’ policy – where required installation components are included in the box – can be the difference between a smooth job and a return visit. For you, the greater appeal often lies in linked sales opportunities and solving known problems. Where product redesign can pre-empt further failure, the benefits are commercial as well as technical.
Beyond EGR, attention is also turning to turbochargers. Once strongly associated with thermal systems, we have now spent more than a decade building our comprehensive turbo ranges. This has grown into a catalogue of over 500 models, covering both petrol and diesel units across major marques, including VAG, PSA and Nissan.
These turbos are manufactured from new – not remanufactured – and validated against OE-level performance benchmarks. The emphasis is on matching the expected engine lifespan, ensuring long-term reliability. For the aftermarket, the ability to supply quality turbo units, supported by proper technical backup and fitting documentation, helps reduce comebacks and build trust with workshop customers.
Euro 6, emissions and the impact on parts supply
As emissions standards evolve, so too does the need for compliance in replacement parts. Many components, especially within the engine efficiency category, must now meet strict design and performance criteria to align with Euro 6 regulations and beyond.
At Nissens, we design, manufacture and validate our parts in line with these requirements, submitting them to internal and external testing against regulatory norms. The goal is to match OE performance while ensuring fitment and longevity, even under demanding conditions.
You also have a role to play in managing workshop use of additives and consumables in emissions-sensitive systems. These products can support performance, but only when used within manufacturer specifications. For example, the wrong additive can damage an EGR system or compromise a turbo if it interferes with oil quality or combustion efficiency. Encouraging best practice here protects both parts and reputations.
Added value
Beyond EGR valves and turbos, our engine efficiency segment is expanding. Intercoolers, oil feed lines, throttle bodies, and EGR coolers are increasingly part of our unified product offering, consisting of a list of over 1,400 parts, covering more than 7,600 OE numbers. These service the bulk of the European passenger car and LCV parc.
Our technical portals now offer structured training, best-practice videos and faultfinding tools to aid the correct installation and diagnostics – giving you further leverage to support your customers beyond just product supply.
For the trade, the emissions repair arena is not just about parts; it’s about offering complete, credible solutions – designed to last and backed by reliable technical insight.
