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I've had problems with my fuel gauge ('04 TD5 Defender) also.
It used to be deadly accurate but about 18 months ago started indicating empty when still at least 20 litres remaining. Consequently, now every time I fill up, I zero the trip meter.
Just recently on a trip from the Central Coast to Katherine in the Northern Territory it started to show an empty tank even though the tank was more than half full. When I first saw this I had only 200Km previously filled the tank so I stopped and looked for a fuel leak. Couldn't find one concluded that the fuel gauge reading was wrong. So continued on my way.
Then I discovered that the fuel gauge would initially show a "correct" reading after first starting the engine and then over about 30 minutes of driving slowly head to a zero reading. Stopping and leaving the ignition off for 15 minutes or so would see the gauge return to a correct reading and then repeat the slow drift to a zero reading again. Most odd.
The gauge kept this behaviour up for about the next week and then went back to behaving as it had for the last 18 months, i.e. indicating about 20 litres less in the tank that actual.
My guess is that either the gauge is faulty or the engine management computer has some setting in it that has been corrupted.
I can't find any "fuel gauge reset screen" with my Nanocom so I'm considering replacing the fuel gauge.
No matter what the problem - there's a solution. You've just got to find it.
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