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 oil bath timing belt deteriorates and clogs the oil pump strainer with debris. The engine dies from oil starvation — bearings, crankshaft, camshaft, and turbocharger are destroyed.

Symptoms: No warning: oil pressure drops, engine runs roughly, then total failure. Belt itself may appear visually intact.

The 2.0 EcoBlue turbocharger sometimes fails before 50,000 km. Cause: belt debris in the oil circuit or excessively long oil change intervals block oil supply to the turbo bearing.

Symptoms: Whistling noise on acceleration, noticeable power loss, blue smoke. Turbo warning light may be absent.

Design-related uneven distribution of EGR exhaust gas causes excessive soot ingestion into the middle cylinders. Soot particles cause abrasive wear via piston rings — compression loss and engine replacement.

Symptoms: Rough idle, elevated oil consumption, white or black smoke, high fuel trim correction values in fault memory.

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 2.5 Duratec 5-cylinder shows frequent ignition coil failures from cracked coil housings at high operating temperatures. Arcing across the spark plug ceramic is typical.

Symptoms: Juddering and misfires on acceleration, rough idle, engine warning light with misfire codes.

The rubber seal in the thermostat housing deteriorates and can block the strainer, restricting coolant circulation and causing overheating tendency.

Symptoms: Poor heater output, coolant loss, occasional temperature spikes on long runs.

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.

A software fault in the park module of the Kuga PHEV and FHEV hybrid gearbox can cause the vehicle to unexpectedly shift into neutral and roll away. Ford recalled approx. 3,600 German vehicles for a software update.

The 8-speed automatic gearbox in the Kuga III shifts harshly under certain conditions and exhibits vibrations when engaging reverse or on hill starts. Software updates only partially improve the situation.

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.