Description

This is a professionally reconditioned BorgWarner BV39 turbocharger, an original equipment (OE) equivalent part for the Ford Focus fitted with the 110 HP KKDA diesel engine between 2003 and 2008. As a genuine OE-spec unit rebuilt by our technicians in Birmingham, it offers a cost-effective and reliable alternative to a new main dealer part, restored to exacting original performance standards.

At Gap Turbos, our reconditioning process is thorough and precise. Each incoming turbocharger is completely disassembled. All components are subjected to an intensive cleaning process, typically using ultrasonic or vapour blasting methods, to remove all carbon deposits and oil residue. Critical parts such as the turbine shaft, compressor wheel, and bearing housing are then meticulously inspected for wear, distortion, or cracks that fall outside of manufacturer tolerances. The unit is then rebuilt around a brand new, high-quality CHRA (Centre Housing Rotating Assembly). This core contains new bearings, seals, and a balanced shaft and wheel assembly. Finally, the complete turbocharger is balanced on our VSR (Vibration Sorting Rig) machines at speeds exceeding 200,000 RPM to ensure it operates smoothly and without vibration, which is a primary cause of premature failure. Common failure modes for the BV39 series often relate to oil contamination leading to bearing wear, or worn seals causing blue smoke from the exhaust as oil enters the intake or exhaust stream. Physical damage to the compressor or turbine wheels from foreign object ingestion can also occur.

What this turbocharger fits

This reconditioned turbocharger is a direct replacement for the factory-fitted unit on the following vehicles:

• Vehicle: Ford Focus
• Engine Code: KKDA
• Engine Power: 110 HP
• Years: 2003, 2004, 2005, 2006, 2007, 2008
• Fuel: Diesel
• OE Part Number: 54399880047
• Alternative Part Number: 038253014R

We offer several services at our Birmingham workshop. We can supply this reconditioned unit on an exchange basis, where you return your old turbocharger to us. Alternatively, you can send us your original unit for us to recondition and return. For local customers, we provide a full drive-in, drive-out service, which includes removal of the old turbo, fitting of the reconditioned unit, and essential related services such as DPF and catalyst cleaning to ensure the entire system is functioning correctly.

For a precise quote and to confirm stock, please contact us with your vehicle’s registration number. All our reconditioned turbochargers are supplied with a 24-month warranty.

Specifications

Vehicle fitment

• Ford Focus

Common faults & troubleshooting

• Blue smoke from exhaust: This is a classic sign of failed internal oil seals, allowing engine oil to leak into either the exhaust housing or the compressor housing and be burnt.
• Loud whistling or siren noise: This indicates a damaged or imbalanced compressor or turbine wheel, which may have been caused by a foreign object entering the system.
• Significant loss of power: If your car feels sluggish and struggles to accelerate, it could be a sign of a seized turbo, a faulty actuator, or a major boost leak from a split pipe.
• Engine management light on: Fault codes relating to ‘boost pressure control’ or ‘charge air pressure’ often point directly to a problem with the turbo’s variable vane mechanism or its electronic actuator.
• Excessive oil consumption: If you are topping up engine oil frequently but can see no external leaks, the oil may be passing through the turbocharger and being burnt in the combustion process.

Fitting notes for this unit

• Replace Oil Feed Pipe: It is mandatory to replace the oil feed pipe and its banjo bolts. The original pipe can become restricted with carbonised oil, which will starve the new turbo of lubrication and cause immediate failure.
• Prime with Oil: Before connecting the new oil feed pipe, you must prime the turbo. Crank the engine for 15-20 seconds without starting it (disconnect the fuel injector wiring) until a steady flow of clean oil is seen coming from the oil feed port.
• Use New Gaskets Only: Use all the new gaskets provided in the fitting kit. Do not apply any form of liquid sealant or gasket paste, especially on the oil drain, as it can break off internally and block oil passages.
• Check Ancillaries: Inspect and clean the intercooler and all boost pipes to ensure they are free from oil residue and debris from the previous turbo failure. Any debris left in the system can destroy the new unit instantly.
• Initial Run-in: Once fitted and started, allow the engine to idle for a minimum of five minutes. This allows oil pressure and flow to stabilise within the new turbo before it is subjected to high rotational speeds under load.
• Torque Settings: Ensure all exhaust manifold nuts and bolts are tightened to the manufacturer’s specified torque settings in the correct sequence to prevent exhaust gas leaks.

Alternative part numbers

This turbo is also referenced by:

• 038253014R — Ford Turbocharger OEM 038253014R (Ford Focus, KKDA, 110hp)

Frequently asked questions