2016 Land Rover Range Rover Sport Fuel system Problems

The underside fuel tank support and shielding system on my 2016 Land Rover Range Rover Sport L494 TD6 diesel, with approximately 85,000 miles, is experiencing significant and premature corrosion and deterioration. An independent mechanic recently brought this condition to my attention during an inspection and documented the corrosion with photographs. The fuel tank support shields and associated structural components are severely rusting, flaking and disintegrating. These components serve not only to protect the fuel tanks but also form part of the assembly responsible for supporting and retaining them. One suspected contributing factor is galvanic corrosion resulting from dissimilar metals used in the assembly. The steel fuel tank support/shield components are attached to an aluminum heat shield, potentially accelerating corrosion at the contact points and mounting locations. I am particularly concerned because deterioration of these components could compromise the structural integrity of the fuel tank mounting system, potentially allowing the fuel tank to become inadequately supported, shift or detach. It could also result in damage to the fuel system and potential fuel leakage, creating a serious safety hazard. This degree of corrosion and deterioration at approximately 85,000 miles raises concerns about premature failure under normal vehicle use. Other Range Rover Sport owners have reported comparable premature corrosion and deterioration of these components. Of particular relevance, NHTSA complaint #11775230 reportedly involves a 2016 Range Rover Sport TD6 diesel with similar fuel tank support/shield corrosion. I am requesting that NHTSA investigate this condition as a potential safety-related defect affecting Range Rover Sport vehicles and determine whether the design, materials or construction of the fuel tank support assembly contribute to premature corrosion and potential failure.

NHTSA ID

11776784

Incident

Nov 9, 2026

I am reporting severe corrosion of the fuel tank shield on my 2016 Range Rover Sport HSE, raising concerns about a potential systemic safety defect. The vehicle has been regularly serviced by Land Rover dealerships and independent mechanics and garage-kept for most of its life. No service provider previously warned us of significant fuel tank shield corrosion. During an unrelated recall visit, Land Rover Princeton identified severe fuel tank shield corrosion and classified the condition as CRITICAL. On November 28, 2025, the dealership estimated replacement at $2,233.02, but parts were backordered. Despite this critical classification, the dealership advised that the vehicle could be driven, while warning that road debris could puncture the inadequately protected fuel tank, potentially causing gasoline spillage and a fire hazard. When we returned in August 2026, nine months later, replacement parts remained unavailable, leaving this critical condition unresolved. Other 2016 Range Rover Sport owners have reported similar corrosion in NHTSA complaints 11715458 and 11739019. More concerning, an owner of an L405 Range Rover publicly reported severe fuel tank shield corrosion, attributing it to galvanic corrosion between dissimilar metals. That owner also claimed Land Rover acknowledged the issue as safety-related and granted a repair credit after a federal complaint. These reports suggest the problem may extend beyond the 2016 Range Rover Sport to other Land Rover models, raising concerns about a broader design or materials defect rather than isolated wear. Given the recurring complaints, potential fuel leakage and fire hazards, and prolonged parts shortages, I question why this issue has not prompted a safety recall. I request that NHTSA investigate the extent of this condition across Land Rover models, its underlying cause, and whether a recall or manufacturer corrective action is warranted.

NHTSA ID

11775793

Incident

Nov 28, 2025

Component: FUEL SYSTEM, DIESEL:STORAGE:TANK:SHIELD Complaint Description: The undercarriage fuel tank protection shield/cradle on my 2016 Range Rover Sport 3.0L Td6 Diesel (L494) has suffered catastrophic, premature rust and perforation. This is due to a known engineering design flaw where incompatible materials (galvanic corrosion) cause the heavy steel shield to disintegrate rapidly under normal operating conditions. The specific structural component failing on my vehicle is the Fuel Tank Skid Plate Shield (OEM Part Number: LR071011). On this diesel model, the nearby Emission/Tank Shield (OEM Part Number: LR090186) is also severely corroded. This is a critical safety hazard: the shield is a heavy load-bearing cradle meant to structurally support and protect the fuel tank. Because the shield is rotting away, the heavy plastic fuel tank is at imminent risk of dropping or shifting while driving, which could puncture the fuel lines, crack the tank, or drag on the roadway, creating a severe fuel leak, road hazard, and fire risk. Land Rover is aware of this structural defect but has not issued a formal safety recall. This component should be recalled immediately to prevent fuel tank detachment.

NHTSA ID

11775230

Incident

Oct 30, 2026

Shortly after purchase of the vehicle on November 26, 2021, the vehicle began experiencing repeated DEF (Diesel Exhaust Fluid), SCR, and DPF system failures, accompanied by dashboard warning indicators, drivability instability, reduced power warnings, and eventual shutdown conditions. The most serious safety concern is that when the DEF/emissions warning activates, the vehicle may enter reduced-power mode and ultimately become non-operable, creating a significant roadway safety hazard. The vehicle has repeatedly experienced conditions where it could lose power, become unreliable in traffic, or shut down unexpectedly after emissions-related warnings appeared. The vehicle required repeated repair attempts beginning almost immediately after delivery, including diagnostics and repairs involving: DEF system malfunction SCR/DPF restriction codes Reduced power warnings Fuel pressure-related faults Emissions-system failures Drivability instability Suspension-related concerns Despite multiple repair attempts by authorized facilities and warranty-related interventions, the same categories of failures continued to recur. This condition creates a serious safety concern because the vehicle can become unreliable or effectively inoperable while being driven, particularly after activation of emissions-related warning systems. The repeated loss-of-power and shutdown-related behavior creates risk during normal roadway operation. I am requesting review of the recurring emissions-system failure pattern, drivability instability, and operational shutdown behavior associated with this vehicle.

NHTSA ID

11741124

Incident

Dec 1, 2021

The fuel tank support sheet metal has corroded away such that the fuel tank is not supported on the passenger side and may fall from the vehicle. This could cause sudden failure of the vehicle to be operated and possible fire from leaking fuel if the tank falls out.

NHTSA ID

11739019

Incident

May 15, 2026

Fuel tank cradle/support is rusted and might cause fuel tank to fall.

NHTSA ID

11724682

Incident

Mar 15, 2026

The Diesel Exhaust Fluid system on my 2016 Range Rover Sport has a recurring defect that triggers the warning “Incorrect Diesel Exhaust Fluid Quality Detected” followed by a “No engine starts in XX miles” countdown. This defect has happened repeatedly over several years despite multiple repairs including injector replacement, injector housing replacement and eventually a complete DEF tank assembly replacement. The failure always returns. This defect disables the vehicle and creates a safety risk because the car will eventually refuse to start, which can leave the driver stranded without warning. The problem appeared again this month, and the vehicle displayed the countdown message even though only OEM DEF fluid was used. Land Rover’s own internal service bulletins describe this issue, but dealerships have been unable to permanently repair it. I was instructed by Land Rover corporate to bring the vehicle in for a goodwill review, but instead I was told I would need to pay for diagnostics, and corporate later stated they would not cover repairs at all. A respected independent garage reviewed my service records and told me the dealership should have performed a BlueDEF regeneration procedure. They also told me this is a known and continuous problem on these vehicles and that it will never go away without a redesigned system. This is a long-standing emissions-related defect that repeatedly renders the vehicle non-operational and forces owners into unsafe situations. There is no permanent fix available through the manufacturer or dealers. I am submitting this complaint because this defect is widespread on Land Rover diesel models and carries clear safety and reliability consequences.

NHTSA ID

11703706

Incident

Dec 1, 2025

The contact owns a 2016 Land Rover Range Rover Sport. The contact stated while parked at the gas station, the fuel gauge became inoperable. The vehicle was taken to the dealer where it was diagnosed and determined that the fuel sending unit needed to be replaced. The vehicle was repaired, but the failure persisted. The manufacturer was notified of the failure and informed the contact that recalls were VIN-specific and offered no assistance. The contact related the failure to NHTSA Campaign Number: 18V337000 (FUEL SYSTEM, GASOLINE, ELECTRICAL SYSTEM); however, the VIN was not included. The failure mileage was 120,311.

NHTSA ID

11634666

Incident

Dec 15, 2024

Mileage

120,311 mi

The contact owns a 2016 Land Rover Range Rover Sport. The contact stated that while driving at an unknown speed, the check engine warning light illuminated. The vehicle was taken to an independent mechanic where it was diagnosed that the active grill sensor and fuel rail sensor needed to be replaced. The contact stated that the vehicle was taken to the dealer where it was diagnosed that the low-pressure sensor failed and needed to be replaced. The vehicle was not repaired. The vehicle was then taken to the dealer where it was diagnosed that the fuel pump needed to be replaced. The vehicle was not repaired. The manufacturer was notified of the failure and the contact was informed that the VIN was not included in a recall. The failure mileage was approximately 40,000.

NHTSA ID

11505325

Incident

Jan 3, 2022

Mileage

40,000 mi