95' NAS Fuel Gauge not working - Defender Source
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  #1  
Old May 30th, 2014, 08:56 PM
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Kenny
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95' NAS Fuel Gauge not working

Any suggestions,recommendations or known faults?
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  #2  
Old May 30th, 2014, 09:22 PM
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Jason Lavender
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Go VDO!

You checking to make sure you have 12v on it, solid ground, and check the sender line in? Multimeter is your friend.
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  #3  
Old May 31st, 2014, 12:59 AM
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It could be a multitude of things. Is it reading full, empty or something in between ?

Mine quit working this past March, it was stuck at just above 3/4. Mine was a float issue related to coming down off a rock & having the rear step bumper solidly smack a rock which caused a nearly full tank of fuel to cause the float arm assembly to get stuck in the "up" position.

In the mean while, start preparing the bolts that hold on the rear tank skid guard and sway bar by PB Blasting them to get them ready for a possible removal of the tank.
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Old May 31st, 2014, 10:12 AM
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Fuel sender might be on its way out. That was my experience once years ago. I was lazy and simply R&R because dropping the tank twice didn't sound fun or exciting to me at the time. I should have held on to it for bench testing as it could have been a simple fix I suppose.

Clay
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Old May 31st, 2014, 11:51 AM
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Like Clay suggests about having to drop the tank twice, either have a replacement on hand or be prepared to leave your tank out until you can get a new unit (fuel level & pump). The fuel level sender (sensor board & float arm) are specific to the D90, this has to do with the shape of the tank. Be sure to mark the fuel lines as to which hose came off of which nipple on the tank. If you reverse them you'll have to partially drop the tank again to reverse them. Before you reassemble the pump into the tank, plug the new unit wiring into the wiring loom (while out of the tank) and move the float to various locations between full and empty to in sure it's working. This is also how to test the old one to see if this is the problem. Hopefully right now you don't have a full tank of fuel. You may have to put some miles on it to get the fuel level down to a manageable level (use your trip meter).
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Old June 3rd, 2014, 10:18 PM
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Ok it appears to be the fuel sending unit...can I replace just this or do I need to replace the whole fuel pump?
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Old June 3rd, 2014, 10:41 PM
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Unfortunately the whole unit. This is because of the little board that sends the fuel level info to the gauge is specific to the the D90 fuel tank configuration.

If you are able (this vehicle is not your daily driver), I'd drop the tank, remove the sender/pump assmb. Hook it back up to the wire-in socket, and move the level arm to several spots to see if the gauge moves. If not THEN order the replacement part. It's pretty pricey so shop around 1st.

You ill need a "strap wrench" get get the "nut" off the top of the fuel/sender unit. The nut is like one on a "bell jar", you know the type people can their own jelly's in. Mark it's position so you get it about the same tightness when you reassemble. Also mark the fuel hos and nipple so you get the hoses back on in the right position.

If you haven't yet, start PB Blasting those 8 bolts that will have to come off, 4 for the skid plate 4 for the sway bar.
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