Popular mid-size family SUV offering good practicality and driving dynamics. The third-generation Kuga competes with the Nissan Qashqai, Peugeot 3008, and Mazda CX-5. The 1.5 EcoBoost three-cylinder engine is an improvement over the problematic 1.6 but still carries risks of coolant intrusion into the cylinder which can destroy the engine. Ford updated the engine block design in 2019 to address the issue, so later cars are safer. Main concerns are electrical problems (SYNC 3 freezing, keyless entry battery drain, HUD malfunctions), carbon buildup on direct injection valves, Powershift dual-clutch transmission failures if fitted, and the PHEV battery fire recall. Verify fire risk recall 22S43 completed on 2020-2022 models and panoramic roof adhesion recall 22S58 on 2021 builds. Good handling for the segment but not as reliable as Japanese rivals.
Coolant intrusion into cylinder (engine block failure)€4,500 - €10,000
Early 1.5 EcoBoost engines prone to cracked blocks allowing coolant into combustion chamber · more· less
The 1.5 EcoBoost M8DA engine (before 2019 redesign) is prone to coolant leaks into the combustion chamber due to cracked engine blocks. Ford issued a Technical Service Bulletin for vehicles built before April 6, 2019, addressing low coolant level, white exhaust smoke, and rough running. The correction involves replacing the short block and head gasket. Ford updated the engine design in 2018/2019, and Euro 6.2 versions are the revised blocks brought in to deal with the overheating and coolant intrusion issues. A Ford dealer quoted £7,400 for a new engine plus £1,500 labor (approximately €8,900-10,000 total). Specialist suppliers like Pumaspeed offer replacement engines for around €3,600 plus €1,500 labor. Symptoms include gradual coolant loss without visible leaks, white exhaust smoke on startup, and rough running. Cars built from 2020 onwards have the updated block and are significantly less affected.
SYNC 3 infotainment system freezing€400 - €1,200
Screen freezes, DAB signal loss, GPS errors, and random cursor scrolling · more· less
SYNC 3 freezing and glitches are common complaints on Kuga Mk3. Symptoms include frozen/laggy screen, loss of DAB signal, inability to maintain stable phone connections, frozen sat nav, cursor randomly scrolling across the screen, screen flickering from light to dark, and GPS symbol crossed out. Quick fix: press volume and fast forward buttons simultaneously for 5 seconds to reset. If basic resets don't work, disconnecting the battery for 15 minutes allows the APIM (Accessory Protocol Interface Module) to fully reset. The APIM module itself may fail, requiring replacement at €400-1,200 including labor. Some screen failures are hardware-related and require screen replacement. The voice control module can also prevent system shutdown, requiring dealer intervention. Electrical issues are often caused by poor grounding, moisture intrusion, or aging control modules.
Keyless door handles stay activated draining 2 amps overnight · more· less
Known issue particularly affecting Kuga Mk3 models (CX482) from 2019-2023. The proximity switch on the door handle can stay activated, drawing 2 amps overnight and draining the 12V battery. Symptoms include warnings on FordPass app stating "Remote features disabled for battery optimization," remote services stopped, and all-door keyless entry disabled when the car enters deep sleep mode. Ford has issued software patches that resolve the issue - get the car updated at the dealer. Temporary workaround: turn off keyless entry and auto updates in vehicle settings. The battery itself may need replacement (€150-250) if repeatedly deeply discharged. Labor for diagnosis and software update costs approximately €100-150.
Wet-clutch Powershift gearbox suffers mechatronics faults and clutch wear · more· less
The Kuga Mk3 uses the wet-clutch version of Ford's dual-clutch automatic (not the vastly more troublesome dry-clutch variant from Fiesta/Focus). However, reliability issues persist. Common symptoms include shuddering, hesitation, rough shifting, clutch slippage (especially when gearbox is warm), and erratic gear changes when hot. The mechatronic unit is the weakest point - approximately 8 out of 10 repairs involve replacing this part. Temperature-related behavior is common: gearbox changes normally when cold but becomes erratic as it warms up. Repair costs: mechatronic repair/replacement €1,500-2,500, clutch pack replacement €1,200-2,000, full transmission rebuild/replacement €2,500-3,500. Software updates can sometimes resolve shifting issues. Manual gearbox Kugas are significantly more reliable.
Carbon buildup on intake valves€400 - €700
Direct injection allows oil blow-by to accumulate on valves and ports · more· less
The 1.5 EcoBoost uses direct injection, which sprays fuel directly into cylinders rather than washing intake valves clean. Oil blow-by from the crankcase ventilation system sticks to intake ports and valves, causing carbon buildup. Symptoms include rough idling, reduced engine performance, poor fuel economy, and hesitation on acceleration. Carbon buildup becomes notable after 80,000-100,000 km. Walnut blasting is the proven cleaning method, costing €400-600 at repair shops (mostly labor). Mechanics recommend cleaning intake valves every 50,000 km to prevent severe buildup. Using top-tier fuel helps reduce carbon accumulation. Fuel injector clogging is also common on this engine, requiring cleaning or replacement every 100,000 km.
Actuator sticks from gentle driving causing limp mode and EPC warning · more· less
The turbo wastegate actuator tends to stick if the car is driven too gently or only for short trips, as carbon builds up. Symptoms include EPC (Electronic Power Control) light, limp mode, loss of power, and turbo underboost codes. Ford typically won't sell the actuator separately. Actuator-only repair at specialist costs around €600-750, but if turbo internals are damaged from running with a stuck wastegate, full turbo replacement runs €1,500-2,500. Using premium fuel and regular spirited driving helps prevent this issue. On some older turbos, a seized wastegate requires full turbo replacement as there are no serviceable parts. Occurs typically between 80,000-120,000 km.
Suspension knocking noise€300 - €800
Worn control arm bushings and sway bar links cause knocking over bumps · more· less
Some Kuga models develop knocking sounds and poor ride quality due to worn suspension components, particularly on higher-mileage vehicles (over 80,000 km). If control arm bushings are severely worn, metal-to-metal contact creates knocking sounds over bumps. Sway bar links and bushings also wear, producing clunking noises. Control arm bushing replacement costs approximately €300-500 for parts and labor (both sides). Sway bar links cost €100-200 to replace. Front strut mounts can also wear, adding another €200-300. Aggressive driving or rough roads accelerate wear. Inspect thoroughly before purchase, especially on cars used for delivery or driven on poor road surfaces.
Active grille shutter failure€200 - €600
Shutter jammed by debris triggers engine malfunction light · more· less
The active grille shutter system can trigger the engine malfunction light (EML) with fault code U0284 "Lost Communication with Active Grille Air Shutter Module A". Common causes include debris (stones, leaves) jamming the shutters or broken plastic pins. If the control system detects a fault, shutters default to open position; if always shut they're probably jammed. Symptoms include cooling fans running constantly and malfunction indicator lamp illuminated. On diesel models, jammed shutters prevent DPF regeneration from completing properly. Diagnosis requires an OBD-II scanner capable of reading all modules. Repair involves cleaning debris (€100-150) or replacing the shutter assembly and motor (€400-600 including labor).
Head-up display (HUD) malfunction€300 - €900
HUD screen detachment, flickering, or complete failure · more· less
HUD issues reported on ST Line X models include the screen becoming detached from the dashboard (resolved with double-sided tape in some cases), settings becoming unavailable after battery disconnection, and communication errors (diagnostic code U0158 "Lost Communication with Head Up Display"). Third-party OBD2-based HUDs don't work properly on PHEV models due to interference when the electric motor is running. HUD module replacement costs €300-600 for the part plus €200-300 labor. Some issues are software-related and can be resolved with dealer updates. The most common failure is loss of power or ground to the HUD module, requiring electrical diagnostics.
Moderate reliability with expensive electrical and powertrain risks
The Kuga Mk3 finished 55th out of 76 cars in the What Car? Reliability Survey with a score of 90.3%. Ford as a brand ranked 24th out of 30 manufacturers in 2020, with 15% of owners reporting faults. The 1.5 EcoBoost engine is significantly more reliable than the 1.6 it replaced, particularly 2020+ models with the updated block design. However, electrical gremlins (SYNC 3, keyless entry, HUD) are frustratingly common. The Powershift automatic transmission remains a weak point - manual gearbox models are notably more reliable. Budget €300-550 annually for likely repairs beyond routine maintenance.
Pre-Purchase Inspection Checklist
General checks
Service history Complete Ford dealer or specialist records essential. Verify oil changes at proper intervals (every 12 months or 18,000 km).
Tires Check tread depth, age (date codes), and uneven wear. Sizes: 225/65R17, 225/60R18, 225/55R19, 245/50R19, or 245/45R20 depending on trim.
Cold start Must start engine completely cold. Listen for unusual sounds, check for white exhaust smoke.
Test drive Minimum 20 minutes including highway speeds to get powertrain fully warmed up.
Specific for this vehicle
Check coolant level and condition Low coolant or repeated top-ups indicate potential engine block issue. Look for white residue in coolant reservoir. No coolant leaks visible on ground doesn't mean no problem - internal leak is common.
Cold start white smoke test White exhaust smoke on cold start indicates coolant burning in cylinders (serious engine problem). Let car sit overnight before test.
Test SYNC 3 infotainment thoroughly Test all functions: navigation, phone pairing, DAB radio, screen responsiveness. Try software reset (volume + fast forward for 5 seconds) to see if issues recur.
Keyless entry battery drain test Ask seller if car can sit for 7-10 days without driving. Check FordPass app for "battery optimization" warnings. Test all door proximity sensors.
Automatic gearbox operation (if equipped) Drive for 15+ minutes until gearbox is fully warm. Feel for shuddering, jerky shifts, hesitation between gears, or clunking. Cold operation may seem fine but problems appear when hot.
Verify recall completion Fire risk recall 22S43 (2020-2022 models), panoramic roof adhesion recall 22S58 (April-November 2021 builds), PHEV battery recalls 20S42 and 24S79 (if applicable). Contact Ford with VIN.
HUD and electrical accessories Test head-up display (if fitted), all warning lights, parking sensors, cameras. Check for error messages after 10+ minute drive.
Active grille shutter function Use OBD scanner to check for U0284 fault code. Listen for constant fan noise which indicates stuck shutters.
Check engine warning lights during drive Any EML (engine malfunction light) or EPC light during test drive is a red flag. Could indicate turbo, emissions, or sensor issues.
Inspect panoramic roof (if fitted) 2021 models particularly affected by adhesion recall. Check for wind noise, leaks, or any separation around edges.
Keyless entry battery drainSoftware update available at dealer
Contact Ford dealer with VIN to verify all recalls completed. The PHEV battery recalls are particularly serious - affected owners were instructed not to charge their vehicles. The fire risk recall 22S43 involved modifying the engine undertray and radiator cowling to prevent oil pooling. Always verify recall status before purchase.
Warranty Status
Factory warranty (3 years / 100,000 km)Expired on 2020-2021 models
Ford Protect extended warranty (1 year)€400-500/year
Ford Protect extended warranty (2 years)€500-600/year
Ford Protect extended warranty (3 years)€600-700/year
All 2020 Kugas are now outside their original 3-year factory warranty. Ford Protect extended warranty is available through dealers, though prices vary significantly between dealers. The first year of factory warranty is actually manufacturer coverage; years 2-3 are Ford Protect (a third-party insurance policy). Consider extended warranty given the electrical and transmission reliability issues.
This report is for informational purposes only and does not constitute professional advice. Estimates may be inaccurate. Always have a qualified specialist inspect the vehicle before purchase. We accept no liability for decisions made based on this information.