borland

Finding a replacement oil level sender boot can be a challenge. The factory boot becomes very brittle so that it usually breaks upon removal and an exact replacement is not available from Porsche.
I noticed the factory horns and fuel pump uses connector boots that are very similar. I also noticed that most Bosch 044 fuel pumps are sold with replacement rubber boots and connectors.
I couldn’t locate one of those factory horn or fuel pump boots, but did find an eBay seller that was selling a Bosch 044 fuel pump connector kit for $10 which included shipping.



Here’s the boot installed on my 90’ S4.



The boot is a little tricky to install over the sender wire/female connector,



You’ll need some help with dielectric and a homemade tool to stretch the small wire opening.



Notice the strip of sheetmetal that I wrapped around the Philips screwdriver. The trick is to install this metal sleeve to aid inserting the sender wire/female connector through the boot. Using the grease, you can insert both the screwdriver and sleeve, then with the sleeve inside the boot, remove the screwdriver.



With the sleeve installed, push the sleeve and sender wire end into the boot. You then remove the sleeve from the other end of the boot and the assembly is complete.
With the boot installed, its still very easy to reconnect to the sender.

Mrmerlin

very crafty, nice update

Herman K

+1 I've been without a cover to long

Landseer

I need em. Thanks.

Also, in the 944 PET, electrical section, are various connectors with part numbers for ordering from porsche. Some look like they would work for various 928 applications and some have 928 part nos.

Whitesands

very ingenious and well done, mine is naked at the mo.

Dwayne

Excellent idea and a creative solution. THANKS!

blown 87

I have found that a GM HEI distributor boot works very well, the MSD ones are cheap and easy to get.

gbgastowers

I came across the idea of painting exposed or damaged wire insulation with dishwasher rack (vinyl) repair paint. I think this works as insulation and doesn't conduct but insulates. Any problems with this idea? Gunar

Landseer

They make a liquid electrical tape like that. Starbright makes it, its in a little can with paint brush under the cap. I use it sparingly. If there is a lot of damage it seems better to replace the wires.

Gary Knox

I found that the original part is a 944 part number about 8 or 9 years ago. Bought one from 928 International at that time. Don't know whether it is still available, but Jeannie or Roger or Mark could probably find out for anyone.

Gary Knox

DZGunner

Are these still being sold on ebay? I'm replacing my fuel pump and I need these.

Hilton

Hmm.. If you can't find the cheap ebay alternative, there's a factory part no. for boots.

I ordered some before - will go grab a photo and part number from the garage.

edit: Its actually the boot for the oil pressure sender 928 612 497 00 - not sure whether it would fit over the oil level sender stub as it doesn't look long enough?

FredR

Hilton,

Those look like the ones that are no longer available- grrrh!

Regards

Fred

ROG100

928 612 497 00 is available but a little pricy at $10. Fits the oil pressure sender connection as well as the pressure sender on top of the dryer.

I have ordered a lot of different boots for the level sender but none have been a good alternative - I continue to search.

I have used self vulcanizing tape with good effect.

FredR

roger,

Just about every boot on my engine wiring has dropped to pieces, the shrink wrap is like bakellite, my anti knock sensors are working OK [according to ST2] but both harness connectors fell apart-took a little bit of imagination to frig something. Wiring I have had to frig a little here and there and if i had to take my 928 to the damp and cold UK I reckon it would not last two minutes before it stopped working!

My GTS kit does not seem to be holding together as well as my late S4 did but then I tend to forget that my GTS is now about 6 years older than my S4 was when some tw*t on a mobile phone clipped me some 8 years ago and wrecked my beautiful late S4.

I like the idea of the self vulcanising tape- will have to get you to pop some into my next order which doubtless is about due given the pending list of to do items.

Regards

Fred