From: barryorlando@hotmail.com
Sent: Tuesday, August 12, 2003 11:16 PM
To: 928
Subject: [928] Oil Level Sender Boot Replacement

When I replaced my oil pan gasket, I was unable to reuse the old and
brittle oil level sender boot.   Unfortunately, Porsche doesn't sell the
boot as a replacement part; it only comes with a new engine wiring
harness.

Here's a simple way to manufacture a replacement rubber boot for your oil
level sender connector.   You'll need the following.

- Porsche, Part #  928.612.497.00,  Protective Cap, $3.96.
- 3/8" rubber vacuum tube cap (Usually sold as a set of various sizes in
most auto part stores, about $2).

The Protective Cap listed above, is the one that covers the electrical
connectors to the low A/C pressure switch, located in front of the
radiator on S4's.  The cap fits great over the sender, but lacks enough
head room for the wire and connector; so you'll need to extend the top of
the cap by about 3/8", using the 3/8" vacuum tube cap.   Use a razor blade
to cut off the top and make the extension.   Glue it back together using
contact cement and use some sand paper to smooth out the new mating edges.
 I reused the cut off top.  Optionally, you can coat the outside of the
new rubber boot in liquid electrical tape.

The fun part is installing the boot over the electrical connector.  
First, coat with dielectric grease, the connector and the end of a small
Phillips screwdriver.   Then, insert the Phillips screwdriver down inside
the cap and out the end.  This widens the boot end opening enough to slip
the connector and wire thru while withdrawing the screwdriver at the same
time.

Not as cheap as electrical tape, but a fun project and one that looks
stock.

Barry
90' S4, Slate Metallic





-----Original Message-----
From: mlschmidt@sprintmail.com [mailto:mlschmidt@sprintmail.com]
Sent: Wednesday, August 13, 2003 1:41 AM
To: 928
Subject: [928] Re: Oil Level Sender Boot Replacement


>When I replaced my oil pan gasket, I was unable to reuse the old and
>brittle oil level sender boot.   Unfortunately, Porsche doesn't sell the
>boot as a replacement part; it only comes with a new engine wiring
>harness.

Nope. It is available from Porsche separately from the wiring harness.
There are a number of electrical terminals, plugs, connectors, and boots
that you'll be told aren't available separately for the 928, because they
aren't shown on the PET parts program in the 928 section. Many of the same
parts are used on other models, and are shown on the PET program in those
sections though. If you look in the electrical section for the 944, you'll
find several pages of those parts that aren't listed separately for the
928. On one occasion a plug I needed had the part number molded right into
it. The parts guy at the dealership asked what kind of car it was for and
then the part number. When I said it was for a 928 and gave him the number,
I was told it wasn't available separately, and I had to buy the whole
wiring harness to get it. I then told him it was for a 944, gave him the
same part number again, and he had just the plug for me the next morning.
I've gotten several electrical related parts that way already, including
that rubber boot for the oil level sender. The Porsche part number for the
rubber oil level sender boot is 113 927 249.

Mike Schmidt
'88 928S4 Auto Black/Black "PORSCHE" cloth
PCA Chicago Region