Ford Kuga 1.5 EcoBoost Mk3

A significant recall (R/2023/080) affects Kugas built from July 2019 to December 2022 with the 1.5 EcoBoost engine. The fuel injectors can develop cracks, allowing fuel to leak onto the cylinder head near the exhaust manifold, creating a fire risk. Ford's interim fix involves installing a drain tube to divert leaked fuel away from hot surfaces, plus a software update to detect fuel pressure drops and reduce engine power as a warning. A permanent fix is still being developed. This recall is free of charge, but verify it has been completed on any car you inspect. If the recall work has not been done, costs are zero since it is covered, but driving an unrepaired car poses a genuine safety risk.

Like all direct-injection engines, the 1.5 EcoBoost Dragon accumulates carbon deposits on the backs of the intake valves because fuel is not sprayed across them. The Dragon has dual injection (port + direct) which helps somewhat, as the port injectors do wash the valves at certain operating conditions. However, carbon buildup still occurs, particularly with frequent short trips. Symptoms include rough idle, hesitation, and slightly reduced fuel economy, typically noticeable from 60,000-80,000 km. Walnut blasting is the standard cleaning method, costing approximately €350-600 at a specialist. Regular motorway driving and quality fuel help delay the problem.

The water pump on the 1.5 EcoBoost uses a plastic impeller that can degrade or detach from the shaft over time. When this happens, coolant circulation stops and the engine can overheat quickly. Early symptoms include increased engine temperature, poor cabin heating, or an audible grinding/whining noise from the pump area. The recommended replacement interval is around 70,000 km. Replacement costs €400-800 depending on workshop choice, as the timing belt should ideally be replaced at the same time. Catching this early prevents the much more expensive scenario of engine overheating damage.

A widespread issue on the Kuga Mk3 where the dashboard displays an 'Emergency Call System Malfunction' warning. This is caused by software problems in the Telematic Control Unit (TCU) that handles the EU-mandated eCall system. While not a safety risk for driving, it means the automatic emergency call feature may not work in an accident. A Ford dealer software update usually resolves it, costing €100-150 for the diagnostic and programming time. In some cases, the TCU module itself needs replacement, pushing the cost to €300-500. The warning often appears intermittently and may be dismissed temporarily by pressing OK.

Some owners report the SYNC 3 touchscreen going completely black, requiring a manual reboot (hold power + skip right for 10 seconds). In most cases, this is a software issue resolved by a system update at a Ford dealer for around €100-200. In rarer cases, the APIM (Accessory Protocol Interface Module) hardware fails and needs replacement. An aftermarket APIM runs €300-500 installed, while a Ford dealer replacement can cost €600-800. The issue is more annoying than dangerous, as vehicle controls continue to function normally.

Kuga vehicles built between August 2021 and March 2022 may have a damaged oil separator (cylinder head breather), which can cause oil to leak and potentially accumulate near ignition sources in the engine compartment. This is a separate recall (22S21) from the fuel injector issue. The fix involves inspecting and if necessary replacing the oil separator and seals at no cost to the owner. If the recall has been completed, this is a non-issue. Approximately 35,900 vehicles were affected in Germany alone.