MajorCommonEngine

Ford Everest: 2.0 bi-turbo (YN2S) intercooler and boost hose failure - bang then limp mode

2.0 bi-turbo (YN2S) intercooler and boost hose failure - bang then limp mode is a common engine fault on the Ford Everest on the 2018–2022 cars, and we rate it major. Putting it right costs $200 to $1,800 at New Zealand independent workshop rates. Below is what goes wrong, the symptoms to notice on a test drive, where to look, and what to ask the seller before you hand over any money. It is one of 16 documented faults on the Ford Everest.

Vehicle: Ford Everest
Only on: Bi-Turbo / twin-turbo
Engine: 2.0L
Years: 2018–2022
Fuel: diesel
System: Engine

This page covers the Ford Everest as a model. Some faults only affect particular engines or build years — enter a plate below to narrow the list to one car.

All Ford Everest faults16 documented faults on this model

What you are looking at

No photograph available

We do not hold a verified photograph of the Turbocharger yet. We would rather show none than show a picture of a different part.

What goes wrong

The 2.0 bi-turbo runs over 30 psi of boost through a factory intercooler with plastic end tanks crimped onto an aluminium core, plus plastic and rubber charge pipes. Heat and boost fatigue these parts, and the classic failure is a loud pop under load followed by a big loss of power and the engine dropping into limp mode. Tanks lifting off the core are more likely on tuned engines, which run extra boost. It is not usually engine-damaging if caught, but a split hose can let dirt or oil into the intake, and many owners fit aluminium intercoolers and silicone hoses as a fix.

What you would notice

Loud bang or pop under acceleration or while towing
Sudden loss of power and engine warning light
Whooshing or hissing sound when boost comes on
Oily residue around the intercooler pipes or front bumper area

How to check it

Where to look. Front-mounted intercooler behind the grille and bumper, and the charge air pipes between the turbos, intercooler and intake manifold

With the bonnet open, use a phone torch to follow the large black charge pipes from the turbos to the intercooler behind the grille and on to the intake, looking for split rubber, oily wet joints or loose clips. Look through the grille at the intercooler tanks for oil staining where plastic meets the aluminium core. On the test drive, accelerate firmly up a hill and listen for a hiss or whoosh as the boost builds, and make sure power does not suddenly drop away. Ask whether the engine has been tuned or has an aftermarket intercooler. If a workshop inspection is possible: Have the workshop do a smoke test of the intake and boost system and read stored boost pressure codes.

Parts involved: Turbocharger.

What it costs to put right

$200 to $1,800 at New Zealand independent workshop rates. That is for this job on its own, not for the car.

An estimate, in NZD, for the repair as normally carried out. What a specific car costs depends on which part has failed and what it damaged on the way — treat this as the floor for a negotiation, not a quote.

Ask the seller

“Has the intercooler or any boost hose been replaced?”
“Has the engine been tuned or chipped?”
“Has it ever gone into limp mode with a bang?”

Now check the Ford Everest you are actually looking at

Everything above is true of the model, and it is free. What it does not tell you is whether THIS car has been looked after: its odometer history and whether the reading has ever gone backwards, whether there is still money owing on it, whether it has been reported stolen, how many owners it has had and what it is really worth today. That comes from the official records for that plate. Enter the plate for the free details, or get the full history and a market valuation from $13.49.

Not sure what you would be paying for? See what a full KickTyres check includes.

Where this comes from

The failure described above is documented in the sources below. The inspection instructions and the cost estimate are KickTyres’ own interpretation of them.

Unsealed 4X4 (AU) - Ford Everest common problems: 2.0 bi-turbo intercooler pipes going pop under 30 psi plus boost, loss of power and limp mode
Harrop (AU) - Ford PX3 Ranger 2.0L bi-turbo intercooler: OEM plastic end tanks crimped to the core known to crack or lift off
Fenix Cooling NZ - Ford Ranger 2.0L twin turbo intercooler: factory plastic and alloy intercooler replaced for reliability

Ford Everest buyer questions

Is 2.0 bi-turbo (yn2s) intercooler and boost hose failure - bang then limp mode serious on a Ford Everest?

We rate it major and common on the Ford Everest. The 2.0 bi-turbo runs over 30 psi of boost through a factory intercooler with plastic end tanks crimped onto an aluminium core, plus plastic and rubber charge pipes. Heat and boost fatigue these parts, and the classic failure is a loud pop under load followed by a big loss of power and the engine dropping into limp mode. Tanks lifting off the core are more likely on tuned engines, which run extra boost. It is not usually engine-damaging if caught, but a split hose can let dirt or oil into the intake, and many owners fit aluminium intercoolers and silicone hoses as a fix.

How much does it cost to fix on a Ford Everest?

$200 to $1,800 at New Zealand independent workshop rates. That figure is for this job on its own. A car showing the symptoms on this page is usually worth either walking away from or negotiating down by at least the repair figure.

Which Ford Everest years are affected?

Our research records this fault on the 2018–2022 Ford Everest. Build dates move around, especially on imported cars, so treat the range as the years to look hardest at rather than a guarantee either way. The official records tell you the exact build and first registration date for the car in front of you.