Ford Escort RS Cosworth TB3403 Turbo Restoration and Hybrid Upgrade by BG Turbo

Presentation of the Ford Escort RS Cosworth

The Ford Escort RS Cosworth, produced between 1991 and 1996, is one of the most iconic homologation sports cars of the 1990s. Developed for Group A rally competition, it is powered by a 2.0L turbocharged 16-valve engine and equipped with a permanent all-wheel-drive system.

At the heart of its performance lies the Garrett TB3403 turbocharger, reference 452059-0001, designed to deliver strong mid-range torque and reliable high-boost operation. Today, these turbochargers have become increasingly rare, making professional restoration and hybrid solutions essential to preserve both performance and originality.

Turbocharger Restoration by BG Turbo

BG Turbo offers a complete restoration service for the Garrett TB3403 turbocharger used on the Ford Escort RS Cosworth. Each turbocharger is fully disassembled, cleaned, and meticulously inspected by experienced technicians.

Critical components such as the rotating assembly, bearings, seals, turbine wheel, compressor wheel, and housings are measured and checked against manufacturer tolerances. When required, worn or damaged parts are replaced with high-quality equivalent or original-spec components.

Once rebuilt, the turbocharger is dynamically balanced at high speed to ensure reliability, performance, and long service life. BG Turbo can also propose a hybrid upgrade, allowing improved airflow, increased torque, and enhanced power delivery while maintaining compatibility with the original engine architecture.

For restoration or hybrid upgrade requests, please use our dedicated repair form:
https://www.bg-turbo.com/reparation-renovation-reconditionnement

Why Choose BG Turbo for Turbo Restoration in France ?

BG Turbo is a French-based turbocharger specialist workshop, combining artisanal expertise with advanced technical equipment. Unlike mass-production rebuilders, BG Turbo focuses on precision, durability, and tailored solutions for classic, performance, and rare vehicles.

With extensive experience in Garrett turbochargers and Cosworth applications, BG Turbo ensures that each restored or hybrid turbo meets the highest standards of reliability and performance. Our workshop supports customers across France and Europe, offering expert advice and long-term solutions for rare turbocharged vehicles.

Turbocharger Technical Specifications and Parts List

Vehicle compatibility:
1991–1996 Ford Escort RS Cosworth 4x4 (GAL)

Turbocharger identification:
Turbocharger model: TB3403
Manufacturer: Honeywell Garrett

General specifications:
Part number: 452059-5001S
Previous version: 452059-0001
OE numbers: YB1195/2, YB1195D, 6844118, V92HF6K682AA, V92HF-6K682-AA, YB1195/07
Engine codes: YBTN5F, N5F, YBT N5E/F
Displacement: 2.0 L, 1994 cc
Configuration: 4 cylinders, 16 valves
Fuel type: Petrol
Power output: 162 kW / 220 HP
Maximum engine speed: 6000 rpm

Turbo geometry:
Compressor housing angle α: 71°
Turbine housing angle β: 320°
Turbine housing A/R: 0.63

Main turbo components:
CHRA: 409853-0093 (409853-5093S)
Bearing housing: 430027-0039 (430027-0025), water-cooled
Turbine wheel: 451311-0014 (451311-0003), inducer 59.0 mm, exducer 48.35 mm, trim 67, 11 blades
Compressor wheel: 441341-0002, inducer 47.65 mm, exducer 69.0 mm, trim 46, 7+7 blades
Backplate: 409629-0017
Heat shield: 409639-0000 (409627-0000, 103121-0000)
Repair kit: 707897-0001 (dynamic)
Turbine housing: 413746-0005
Compressor cover: 409589-0316 (434157-0001)
Actuator: 430099-0062

Wastegate settings:
Wastegate pressure: 0.410 – 0.480 bar
Wastegate rod lift: 0.38 mm

Gaskets:
Turbine inlet gasket: 409039-0001 (stainless steel, single port)
Turbine outlet gasket: 210242 (steel)
Oil outlet gasket: 210021 (paper)
Oil inlet gasket: 210023 (paper)

Applications:
1991–1996 Ford Escort RS Cosworth equipped with YBTN5F or N5F engine

FAQ

Can BG Turbo fully restore a TB3403 turbocharger for a Ford Escort RS Cosworth?
Yes, BG Turbo performs complete restorations including disassembly, inspection, replacement of worn components, and high-speed dynamic balancing.

Is it possible to upgrade this turbocharger with a hybrid configuration?
Yes, BG Turbo offers hybrid turbo solutions to improve airflow, torque, and power while maintaining engine compatibility.

Do you accept turbochargers shipped from outside France?
Absolutely. Customers from all over France and Europe can safely ship their turbochargers to our workshop for restoration or hybrid upgrades.

Hashtags

#FordEscortCosworth #TB3403 #GarrettTurbo #TurboRestoration #HybridTurbo #CosworthTurbo #BGTurbo #ClassicTurbo #PerformanceCars

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