Did you trace the wires from the pump until the disappear into the body? I had about five wires in that bundle which were damaged - the purple wire with white tracer was so bad that only a few strands of copper were still connected. My gas gauge needle would at one time be on completely empty and fuel light on, and other times would be past full.

Once I repaired all the wires, problem went away. This was just behind the driver's side wheel well about 3-4" past where the wire bundle comes out from the floor.

 

I am telling you, these bundles are crap.

 

I am still having a hard time finding where the problem is...

Jimmy, did you have to remove any wiring from the protective cover (black plastic thingy) to find where yours was exposed? What had caused it?

 

My money is on a dead tired fuel pump pulling more amps then the fuse can handle.
Replace the pump and make this problem go away. Also, consider using an AirTex pump from Advanced for a better/cheaper replacement.

 

FWIW our rover came with a bad pump that was less than 2 y.o. As a mtter of fact it ran before the guy brought it to the house..
At any rate. THE p.o. got a new pump delivered to me, I tested it prior to replacing. The green black wire was bad in the harness... What I did was cut the connector off an use high quality sta-con connectors ( female) to replace it.. Things been running like a top ever since ( knock on wood)
The harness is available through NAPA, Federated. Or do what I did.. But check it as it could save you a few bills..

 

Well I think the problem is in the fuel pump harness. I also have a small hole in the fuel tank. How difficult is it to replace the fuel tank?

 

Noted....

 

Sorry Matt! I missed this post.

My black plastic thingy was already missing for a good 16" or more from where the wires come out of the body and head towards the tank. So, the wires were just hanging out there. IIRC there was even some black wire harness wrap around those wires which had all but fallen off.

If I had to guess on what caused it, it was from being exposed (no black plastic wire loom to cover/protect it) and the tire kicked up garbage which impacted the wires hard enough to damage them (or something smacked it just right while offroading and did the damage). Don't think it was from heat from the exhaust, but I'd have to stick my head up under there again to see how close the exhaust is from the wiring.