Member Since: 21 Feb 2007
Location: England
Posts: 78
Fuel Filler Lid Won't Open
Just been to the fuel station to top up with diesel for the weekend and I couldn’t open the filler cap. I pushed it on the left hand side like normal and the lid didn’t open.
I tried locking and unlocking the car but that didn’t work. I thought it may be the cold, currently -10â°C, so I have even had a hair dryer blowing on it but that didn’t work either.
Thankfully I still have some fuel in the tank but that won’t last too long.
Has anybody got any ideas on what has happened and more importantly what I can do about it?
open the cubby on the inside of the boot on the right hand side, and look/feel for a loop of black braiden sheeve with a light grey grip strip on it. This is the release cable that goes from the electric locking actuator to the pin hold the flap shut - gently but firmly pull this out at the bottom of the loop and you pull it free from the flap there by releasing the flap.
This is a picture of the release actuator kit:
Click image to enlarge
Yes, I've been there myself, but I forced the flap out a I was at the filling station out of fuel (literally) and a big queue behind me But I never got around to replacing the unit on the car before we sold it, so I still have the spare part if someone needs it
17th Dec 2010 9:21 pm
Chancer
Member Since: 21 Feb 2007
Location: England
Posts: 78
You are a life saver! The wife is due to give birth in the next few weeks so I was getting a little concerned at the prospect of not being able to put fuel in the car
Pulled the pin out and it was covered with ice which is what was causing the problem in the first place.
I will put it all back together tomorrow and see if it stll works. If it doesn't I may be interested in that spare of yours I'll let you know.
When you've got it pulled out as now try spraying some WD40 down into the pin end - it's a water dispersant so should further icing up
When putting it back in place be careful not to bend/snap the pin - that's why it got stuck in our D3, SWMBO tried to shut the flap when the central locking was locked
Anyhow - good luck and all the best in the coming weeks to you and your SWMBO
17th Dec 2010 10:57 pm
Chancer
Member Since: 21 Feb 2007
Location: England
Posts: 78
Thanks again for the help MrH.
All seems to be working ok now but I'm still going to take your advice regarding the WD40
18th Dec 2010 2:24 pm
StephenO
Member Since: 15 Feb 2010
Location: Scotland
Posts: 1651
Thanks from me too!!
Just found this post, happened to me tonight and funnily enough, it was -10.
Had the Disco nearly 3 years and didnt realise there was an emergency release!
Cheers 2016 RR Sport Autobiography
2005 D3 Zambezi Silver
1995 Defender 90 300Tdi Coniston Green
1968 Series 2a SWB Bronze Green
Another one to bear in mind it that water builds up and freezes in the flap release/spring thingy which means it does spring open as you'd expect, so a little WD40 on that helps too.
22nd Dec 2010 10:09 am
DeadmanWNC
Member Since: 07 Sep 2010
Location: Peterborough
Posts: 50
I had this the other week. Only had the car a few weeks so I rang LR Assist.
Really helpful bloke said get out the car, lock the car with the key fob, then unlock the car 5 times with the key fob.
The fuel filler popped open.
Apparently 5 unlocks resets all the locks...
Interesting enough, bot LR assist and my local LR stealer said "There is no emergency release for the fuel filler cap!!!"
22nd Dec 2010 10:15 am
biskit
Member Since: 23 Dec 2009
Location: in my Mancave.
Posts: 1365
Yeh local dealer told me to force it using a screwdriver,wonder if anyone has told them yet.
Just had the big panic of my fuel cap not opening at the forecourt. Was even trying to pry it open. Then had to abandon my effort.
Got straight to this thread and hurrah the unlock 5 times method worked!
Cheers guys.
17th Dec 2013 8:08 pm
Karl_c
Member Since: 06 Apr 2014
Location: Essex
Posts: 68
Thanks deadman happened to the mrs today told her what you said all good again bloody thing seems every week I'm resetting something ha
25th Apr 2014 2:06 pm
Daf
Member Since: 21 Aug 2007
Location: Wales, mun ;-)
Posts: 164
Had to reach in and pull the cable. I now can't get it to click back into the tube. I can slide it down the tube but it won't click in place. Do I need brute force or a tool like pliers?
Having a dodgy sounding release motor on mine, I investigated this last weekend, found that if I follow the cable up to the flap, just beyond the point where it is fixed flap release, get hold of the next (felt like a large plastic washer) I could just pull the washer and it would release the pin, no need to remove the cable, still locks and unlocks ok.
30th Jan 2015 5:31 pm
Daf
Member Since: 21 Aug 2007
Location: Wales, mun ;-)
Posts: 164
If you've tugged the cable and the whole lot has come out of the tube then you can push it in with your hand. Slide in the 5cm length of plastic that's on the end of the cable into the tube. The cLip, which is in two parts is just shoved into the tube to lock it in place. There's no discernible click, just shove it back into the tube so all sides are flush with it. Seems to work.
Thanks to the Forum members once again, my filler flap wouldn't open when filling up deep in the Scottish Highlands today. Fortunately enough phone signal to search the forum there and then on the forecourt, found this thread and 5 presses of the unlock button and flap popped open!!!
Panic over! Wes
2006 Discovery TDV6 7 seats
1967 Series 2a 88" Tilt
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But I never got around to replacing the unit on the car before we sold it, so I still have the spare part if someone needs it 
2005 D3 Zambezi Silver
