Turbos 46 www.aftermarketonline.net MAY 2025 Melett, a leader in precisionengineered turbochargers and components for the global automotive aftermarket, is serving up expert guidance on common turbocharger failures — and how to prevent them for optimal performance. Insufficient oil flow is a major risk, as blocked oil feed pipes, worn oil pumps and sludge build-up from improper shutdowns are common causes of lubrication failure. Without adequate oil flow, turbo bearings can suffer rapid wear and fail. To avoid these issues, Melett recommends priming the oil system thoroughly before fitting a replacement turbo and ensuring oil feed pipes are replaced to remove blockages. Using high-quality, correct grade oil and allowing the engine to warm up properly before driving are simple yet effective ways to extend turbocharger life. Oil contamination remains one of the leading causes of turbocharger failure. The effects of debris from engine wear or poor-quality filters can cause a major issue. Dirty oil can result in significant damage to the turbo’s internal components. Melett advises technicians to purge oil systems after any failure and take care when replacing oil to prevent accidental contamination. Using high-quality filters and replacing oil at the recommended intervals will help maintain peak condition. Overspeeding, which occurs when a turbo operates beyond its intended limits, is another common failure mode. Blocked air intakes, torn air pipes and leaks in the system all force the turbo to work harder, increasing the risk of component fatigue and damage. Melett advises checking air hoses and intake systems for leaks or cracks. Ensuring seals are intact and replacing damaged components can significantly reduce the risk of overspeeding and associated failures. Debris and particles that can enter a turbocharger, whether through servicing or engine wear, pose a serious threat to performance. Tell-tale signs include grinding noises or visible marks on the turbine or compressor blades. To prevent this, inspect and clear all intake pipes and air filters before fitting a replacement. Regular servicing should include a thorough check of air hoses and filters. Blocked diesel particulate filters (DPFs), hot engine shutdown or cooling system leaks can cause lasting damage to internal components. The excess heat leads to carbonisation of the oil within the turbo. Technicians should check cooling systems and DPFs for any blockages or leaks during servicing. Additionally, drivers should be reminded to allow engines to cool after long journeys. www.melett.com Video guides turbocharge support for workshops Nissens Automotive has unveiled two new videos to help technicians to effectively diagnose issues and efficiently install new units. They cover electrically activated turbos and those with an electronic position sensor and are in line with free support provided in various formats, in addition to the manufacture of premium quality aftermarket components. Each video includes common topics such as troubleshooting, best practice, a technical bulletin, learning and warranty terms, and naturally vary when dealing with specific details — whether that’s considering the condition of the electrical connections of the electrically activated turbo, or the vacuum testing requirements of the turbo with the electronic position sensor. Both videos are on the Nissens YouTube channel and available on the Nissens Experts portal, where workshops already fitting Nissens parts will be familiar with the wide ranging additional technical support the company provides. The portal gives aftermarket professionals a broad spectrum of technical information, from training modules and videos to best practice procedures and product information. All are designed to help workshops deliver better customer service and make jobs easier. In common with the rest of the Nissens range, all of its replacement turbos are characterised by excellent product quality, in line with the company’s genuine Nissens quality standards. These benchmarks include undergoing a wide variety of tests and incorporate design and material improvements that contribute to their high performance and durability. A further benefit for workshops is the ‘first fit’ concept, which, in common with every component in the Nissens range, means that whenever extra parts are needed, such as for a turbo’s correct installation, they are included in the box, saving installers time and effort. www.nissens.com Top tech tips for performance
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