RESOLUTION:  Replaced gas tank 4 wire connector

• part shows 5 wires. only 4 used
• cut wires to existing connector 1 at a time
• Soldered in new connector from mercadolivre 1 at a time to insure correct connects
• used black electrical tape to insulate.  I have heat shrink sleeving on the way

Astra 2007 Gas Tank Connector

Observation 

• I measured no voltage across Sender_1  to Sender_2 when I pulled the connector off of the tank lid
• I did measure +12 Volts as labeled – and that is consistent with the pump running.

Inference

• There must be a connection to power or ground to the sender 1 or 2 inside of the tank

Process Notes

• Cut only the 2 wires "to the pump" and connected to new connector – Engine would not start – pump did not run
• Cut the 2 sender wires and connect then – the pump ran and the gas tank meter started functioning.  
• Thus I conclude I do not understand fully how this item is running!

 

YT: How Fuel Senders and Fuel Gauges Work

Operation Notes – Generic

• Resistance:  38 to 180 ohms
• Bimetallic strip with heating coil is heated and bends more with more current
• This means there has to be a source of 12 volts in the circuit 
• Using this heating method makes for a very low bandwidth averaging circuit. 

 

Joao came over and debugged.  He found that the connector is weak / intermittent.  I need a test to confirm. 

MercadoLivre Parts 

• MLsearch:flange bomba combustivel astra
• MLsearch:bomba combustível completa astra
• MLitem: Tampa Flange Da Bomba Bosch Astra Corsa Sedan Vectra Zafira | Compatível com Chevrolet Astra  64 Reais 
• MLitem: Bomba Combustível Universal Flex Sistema Bosch-varios Carros | Compatível com Chevrolet Astra

    

Full Assembly for Astra 2007

1. G:bomba combustivel astra completo
2. MagaLu: bomba+combustivel+astra  – this page has pump and connector parts
3. MagaLu: Bomba combustível astra 2.0 8v flex 2005 2006 2007 2008 – 67147 – 26085 – Chevrolet
4. MagaLu: Chicote da Flange de Combustível Corsa Astra Zafira Celta Vectra – Rainha da Sete
5. MLsearch: plug bomba combustivel astra
6. MLitem: Plug Chicote Tampa Bomba Combustível – Compatível com Chevrolet Astra 2007
7. MLitem: 2-plug Chicote Tampa Bomba Combustível – Compatível com Chevrolet Astra 2007 – this one comes with 2 connectors – one is for the bottom of the lid.  ( per reply of vender ) 

Item #3

Item #4

Item #6

Item #7