Ford Kuga

Continental injectors with a faulty internal coating (vehicles built Feb–Sep 2019). The coating delaminates and blocks the injector. Ford service action: free injector replacement (Ford TSB-20-2335). Affected vehicles: Transit, Ranger, Focus, Mondeo, S-Max, Galaxy, Edge.

Symptoms: Hesitation, poor idle, power reduction, increased fuel consumption, limp mode

Faulty injectors generate excessive soot that prematurely clogs the DPF. On the high-output variant (190 hp), soot also blocks the low-pressure filter of the dual EGR system. Repair requires simultaneous replacement of injectors AND DPF (TSB-20-2335). Replacing the DPF alone does not resolve the issue long-term.

Symptoms: Fault codes P2002, P02EC, P02FA, check engine light, power reduction

The 2.0 EcoBlue uses a wet-running toothed belt to drive the oil pump. Wear of the belt coating generates fine particles that clog the oil pump strainer. Oil pressure loss damages bearings, crankshaft, camshaft, and turbocharger.

Symptoms: No early warning symptoms; once clogged: oil pressure warning, metallic knocking, turbocharger wear, in worst case sudden engine failure

The intake port geometry of the 2.0 EcoBlue directs a disproportionate share of EGR soot into the middle cylinders. Piston rings grind soot into the cylinder wall; compression loss possible from around 135,000 km.

Symptoms: High fuel trim corrections, power loss, oil consumption, injection quantity fault codes, workshop finding: cylinder wall scoring in cylinders 2 and 3

The NOx sensor in the SCR exhaust aftertreatment system fails prematurely. Fault code P20EE is typical. AdBlue consumption increases measurably as the system reverts to a base map. Sensor replacement is relatively inexpensive.

Symptoms: Check engine light P20EE, increased AdBlue consumption, occasional no-start after many km

The 2.0 Duratec HE shows elevated oil consumption from piston ring wear at higher mileage. A clogged crankcase breather aggravates the problem by blowing oil into the intake tract.

Symptoms: Oil consumption above 0.5 l/1,000 km, blue smoke on acceleration, oil vapour from breather hose.

The hydraulic chain tensioner of the 2.0 Duratec HE produces rattling noises on cold start when oil pressure build-up is delayed. Neglected oil changes significantly accelerate chain wear.

Symptoms: Metallic rattling immediately after cold start for approx. 20–30 seconds. On chain jump: engine warning light, misfires.

The Kuga PHEV (plug-in hybrid) was recalled multiple times for fire risk. Faulty charge regulation or defective battery cells can cause overheating and vehicle fire. Multiple separate recall actions up to 2025.

The 1.5-litre EcoBoost engine in the Kuga III — despite revisions from mid-2019 — still occasionally suffers from hairline cracks in the engine block. Coolant enters the combustion chamber or oil circuit.

In 2022 Ford recalled over 36,000 German Kuga PHEV and FHEV vehicles because a defective connecting rod bearing can damage the engine block. Oil can reach hot exhaust components — significant fire risk. As an immediate measure the grille was modified rather than replacing the bearing.

On the Kuga PHEV, the 12-volt starter battery deep-discharges during extended standing because the control unit doesn't regulate standby current draw optimally. Vehicles that aren't moved or charged regularly can be left stranded.