Description

This is a reconditioned BorgWarner BV39 turbocharger for the 1.9 TDI Audi A3 (BKC/BLS engine codes), produced between 2003 and 2009. It is a direct replacement for original equipment (OE) part numbers including 03G253014G and 54399880022, restored to exacting standards at our Birmingham workshop.

The BorgWarner BV-series is a common fitment across the VAG group and is generally reliable. However, after high mileage, certain failure modes become common. The most frequent issue we see is with the internal oil seals. When these fail, engine oil is allowed to pass into the intake or exhaust system, resulting in characteristic blue smoke, particularly on start-up or when lifting off the accelerator. Another common fault is imbalance of the compressor or turbine wheel assembly, often caused by oil contamination. This typically presents as a loud whistling or siren-like noise under acceleration, which will worsen over time and eventually lead to catastrophic failure.

This listing is for a fully reconditioned unit, sold on an exchange basis for your old turbo. At Gap Turbos, our reconditioning process is comprehensive. We completely disassemble the turbocharger, subjecting all components to an intensive cleaning and inspection process. Any parts that do not meet our strict tolerances are replaced with new, OE-specification components, including bearings, seals, and piston rings. The rotating assembly is then balanced on our VSR (Vibration Sorting Rig) to tolerances often finer than the original factory specification, ensuring longevity and performance. We can also supply a brand new unit or provide a complete drive-in, drive-out fitting service. This service includes removal of the old unit, fitting the new turbo, changing the engine oil and filter, and thoroughly cleaning the intercooler, boost pipes, and oil feed/drain lines to ensure a reliable installation.

What this turbocharger fits

• Vehicle: Audi A3
• Engine Codes: BKC, BLS
• Engine Size: 1.9 TDI
• Horsepower: 105 BHP
• Year Range: 2003 – 2009
• Fuel: Diesel

All our reconditioned turbochargers are supplied with a comprehensive warranty. Please contact us with your vehicle’s registration number for a precise quote and to confirm compatibility.

Specifications

Vehicle fitment

• Audi A3

Common faults & troubleshooting

• Loud whistling or siren-like noise under acceleration: This indicates worn bearings or an imbalance in the compressor/turbine wheel assembly, requiring immediate inspection.
• Blue smoke from the exhaust, especially on start-up: A classic sign of failed internal oil seals, allowing engine oil to be burned in the exhaust.
• Significant loss of engine power and poor fuel economy: The variable geometry nozzle (VGN) mechanism may be sticking due to carbon build-up, preventing correct boost pressure generation.
• Engine management light on with ‘boost pressure deviation’ fault codes: The ECU has detected that the turbo is not producing the requested amount of boost, pointing to a leak, a sticking actuator, or internal wear.
• Oil leaks visible on or around the turbo housing: While this can be from connecting pipes, it often points to failing seals within the turbo’s central housing rotating assembly (CHRA).

Fitting notes for this unit

• Crucial: You must replace the oil feed pipe. The original pipe on the BKC/BLS engine is a known failure point, prone to internal carbon build-up which restricts oil flow and will destroy the new turbo.
• Prime the new turbo with clean oil before starting. Use a syringe to inject the correct grade of new engine oil into the turbo’s oil inlet port until it runs out. This ensures the bearings are lubricated on the initial start-up.
• Always use the new gaskets and copper washers provided. Re-using old, crushed gaskets on the oil feed, oil drain, or exhaust manifold connections will result in leaks.
• Perform a full engine oil and filter change. Use only VAG-specification 5W-30 fully synthetic oil (VW 507.00) to ensure correct lubrication and temperature control.
• Disable the engine from starting and crank it for 15 seconds. Before the first start, disconnect the fuel injector harness and crank the engine over to build full oil pressure throughout the system and prime the new feed pipe.
• Inspect the intercooler and boost pipes for contamination. The previous turbo failure may have deposited oil and metal fragments into the system, which must be cleaned out to prevent ingestion by the new unit.

Alternative part numbers

This turbo is also referenced by:

• 54399880022 — BV39 Turbocharger OE 54399880022 (Audi A3, BKC/BLS, 105hp)

Frequently asked questions