Defender's Fuel Flap Sensor Woes: Fix Guide & Costs

Had the same issue with my 2016 Land Rover Discovery diesel last year. The fuel filler flap wiring harness was damaged, causing intermittent sensor signals. My mechanic found corroded wires and a partially damaged connector near the fuel door mechanism. It wasn't a serious problem affecting engine performance, but it needed fixing to clear the check engine light and ensure proper fuel door operation. The repair involved replacing the wiring harness assembly and recalibrating the sensor. Took about 2 hours to complete. Just make sure your mechanic checks the entire wiring harness, not just the sensor itself. Sometimes they'll try to repair the existing wires, but in my case, a complete harness replacement was necessary for a proper fix. Also, get them to check the door mechanism itself while they're at it, these can get sticky with age. If you're worried about your current mechanic, any certified Land Rover specialist should be able to handle this repair. It's a known issue with these models.

Thanks for sharing your experience! That's really helpful to know about the wiring harness issue. I'm planning to have mine checked next week. Do you remember roughly how much you ended up paying for the repair? Also, has everything been working smoothly since the fix, or have you noticed any other quirks with the fuel door?

Hey again! Happy to give you an update on that fuel door issue. I just got the repair done and I can finally say goodbye to that annoying check engine light! The mechanic confirmed it was exactly what I suspected, a faulty wiring harness near the fuel door. The total bill came to 155€, which included replacing the defective fuel filler flap wiring harness and all the labor. Not too bad considering how annoying that warning light was! Since the fix, everything's been working perfectly, the fuel door opens and closes like it should, no more warning lights, and the sensor's reading correctly. Such a relief! It's actually kind of funny how such a small thing can trigger the check engine light, but I guess that's modern cars for you. If you're getting yours checked next week, make sure they look at the entire wiring assembly. Trust me, it's worth getting it done properly rather than trying any temporary fixes. The peace of mind is totally worth it!

Thanks for the follow-up! I actually just got back from the mechanic today. You were spot on about the wiring harness! Took my car to a different shop this time, and I'm so glad I did. The mechanic was super thorough and found some additional corrosion that my previous guy had missed. Total repair cost was a bit higher than yours, came to about 200€ because they had to replace a connector too, but honestly, it was worth every penny. The warning lights are finally gone, and the fuel door's working smoother than it has in years. What a relief to have this sorted! Really appreciate everyone's input on this, helped me feel more confident about what to expect and what questions to ask. Sometimes these seemingly small issues can be such a headache, but having good advice makes all the difference. Now I can finally stop worrying every time I need to fill up! Thanks again for sharing your experience, it really helped me make the right decision about getting this fixed properly.