Smart Forfour Fuel Door Stuck Due to Electrical Failure

Having dealt with a similar issue on my 2006 Smart Fortwo diesel, I can share some repair experience. The fuel flap release button stopped working completely, along with several electrical functions. The root cause was a damaged cable release mechanism and corroded linkage connecting to the fuel door. After trying basic troubleshooting like checking fuses and the emergency release, I had to take it to a workshop. The repair involved: Replacing the complete fuel filler door mechanism, Installing new linkage components, Fixing related electrical connections Total cost was 210€ for parts and labor. The job took about 2 hours to complete. Quick question, are you experiencing any other electrical issues besides the fuel door? Some common related symptoms include: Central locking problems, Dashboard warning lights, Power window issues Knowing these details would help identify if your issue matches what I encountered. Also, have you checked if there is a manual release lever in the trunk area? Some models have this as a backup. Would you mind sharing if you notice any clicking sound when pressing the release button? This could help determine if its an electrical or mechanical problem.

Latest service was done at 110000 KM, just 1276 KM ago. The electric actuator for the fuel door actually started making strange noises about 2 weeks before complete failure, which I should have mentioned. When pressing the release button now, there is no sound at all. Central locking started acting up simultaneously, sometimes works, sometimes doesnt. After reading your experience, it seems our issues are quite similar. The fuel flap problem combined with other electrical faults points toward a bigger electrical issue rather than just a mechanical one. Definitely getting that clicking noise when trying the release button. Did you also experience intermittent key fob issues before the complete failure of the system? At this point, Im wondering if its worth attempting a cheaper repair or just replacing the whole mechanism as you did.

Thanks for those extra details about your Smart Forfour. Your symptoms match my experience exactly, especially the strange noises from the electric actuator before total failure. The combination of central locking issues and fuel filler problems is a classic sign of a failing system. The key fob issues you mentioned are definitely related. In my case, the intermittent key fob function was linked to a deteriorating electrical connection in the fuel door release mechanism that was causing interference with other systems. Based on the mileage you mentioned and the similar failure pattern, replacing the complete mechanism is the most reliable fix. Trying to repair individual components often leads to recurring issues since the entire release mechanism tends to degrade as a unit. The repair cost should be similar to what I paid (210€), though prices may vary. Make sure they check the electrical connections thoroughly during installation, in my case, corroded wiring near the fuel filler area needed attention to prevent future problems. Quick tip: while waiting for repairs, check if your model has the emergency cable release. Its usually hidden behind the trunk lining and can be a lifesaver for accessing the fuel door temporarily.

Based on your description, I definitely think were dealing with the same electrical fault pattern. Makes sense about the key fob connection, that explains the erratic behavior Ive been seeing. Those weird noises from the electric actuator should have been my warning sign. The fuel flap release mechanism failing along with central locking really points to exactly what you experienced. Glad you mentioned checking the emergency cable release, found it behind the trunk panel but its not working either, which probably confirms the whole system needs replacement. Given the similar symptoms and knowing your repair cost was 210€, Ill go ahead and book it in for a complete replacement rather than waste time trying cheaper fixes. Just hoping the wiring near my fuel door isnt too corroded, but at 110000 KM its probably due for renewal anyway. Thanks for sharing your repair experience, really helped confirm what I was suspecting about needing the whole unit replaced rather than just parts of it.