Usage:
3208 Naturally Aspirated Truck Engines
Reference: "Oil Pan Size Identification", in this issue.
Description of Change: The 3208 Naturally Aspirated lubrication system refill capacity (including filter) has been reduced by 2 L (2 U.S. qt) in all applications except those engines with center sump oil pans. Refill capacities for turbocharged engines did not change.
Adaptable To: The new reduced oil refill capacities are in effect with 51Z68765.
Earlier NA engines can be modified by installing a new oil level gauge (See Chart A) and a new 7C4085 Film (oil capacity), appropriately marked for the new refill capacity.
Procedure To Recalibrate Oil Capacity
1. Install the correct new oil level gauge (dipstick) as shown in Chart A to provide the new (reduced) oil capacity. The new gauges are marked for 2 L (2 U.S. qt) between the "Add" and "Full" marks. Some former gauges were marked for 4 L (4 U.S. qt) between "Add" and "Full".
NOTE: The oil capacities of naturally aspirated engines with center sump oil pans did not change. Therefore, some of the former gauges are still available for use in other applications.
2. Install two new oil filters.
3. Install the correct amount of oil for the new, reduced refill capacity (includes filters) as shown in Chart B.
4. Start the engine and allow it to operate for 5-10 minutes. Stop the engine and allow 10-15 minutes for the oil to drain back into the oil pan.
5. Check the oil level using the new oil level gauge (dipstick). The actual oil level should be at, or slightly below the "Full" mark on the new gauge. The actual oil level may be slightly below the "Full" mark, if the pan has been removed and emptied completely. It may take approximately another .5 L (.5 qt) of oil to reach the "Full" mark.
6. Remove the original oil capacity film (decal) from the engine valve cover. Install a new 7C4085 Film. Before installation, punch or mark the box next to the correct (new) oil capacity. The new capacity should be 2 L (2 U.S. qt) less than the capacity marked on the engine's original decal.
Procedure to Calibrate Unmarked Gauges
The 7C5795 and 4N4542 Gauges are used in circumstances where calibration and remarking are required.
The appropriate blank gauge, if needed, can be marked by the dealer. The blank gauges may be too long to fit in some applications, and should be shortened to no more than 12.7 mm (0.50 ") longer than the original gauge in the engine. The two types of unmarked gauges are shown in Illustrations 1 and 2.
Illustration 1. 7C5795 Gauge.
Illustration 2. 4N4542 Gauge.
1. Drain the oil pan, install new filters and add the recommended quantity of oil according to Chart B and the reference article on oil pan size identification, except for 2 L (2 qt). Then, start the engine and let it operate for 5-10 minutes. Stop the engine and allow the oil to drain back into the oil pan for 10-15 minutes.
2. Carefully determine the actual oil level on the blank gauge and make a mark. This is the "Add" mark. Next, add the remaining 2 L (2 qt) of oil and allow it to drain into the oil pan for 10-15 minutes. Carefully determine the actual oil level on the gauge and make another mark. This is the "Full" mark.
3. The total quantity of oil installed in the engine in the above steps should be the same as the new recommended refill capacity. After the blank gauge is marked, cut off the excess gauge length approximately 6.4 mm (.25 ") below the "Add" mark.
NOTE: Refill capacity is the total amount of oil to be installed during an oil and filter change. Do not confuse the amount of oil in the oil pan with the recommended refill capacity. They are not the same. When calibrating or checking the accuracy of a oil level gauge, always perform a complete oil change with new filters and run the engine. Then, see if the actual oil level agrees with the oil level gauge markings.
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An incorrectly calibrated oil level gauge (dipstick) or an incorrectly installed guide tube can lead to overfilling, which may cause excessive oil consumption. If the unit is not sitting level, the engine oil level reading will not be accurate. The oil level indication will change approximately 2 L (2 U.S. qt) when the unit is tilted from 0 to 3 °.
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NOTE: For remanufactured engines, use the above chart and the Reference Serial No. shown on the Engine Information Plate to determine the correct refill capacity.
Oil refill capacities in turbocharged engines did not change. Turbocharged engines use the same oil pans in various applications, but have different refill capacities. The refill capacities listed in Chart B are for naturally aspirated engines only.