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Title: PSI 8.8L Engine Oil Pan Gasket Leaks

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Applies To: All PSI 8.8L LPG and Gasoline Engines

Change Log

Countries: CANADA, UNITED STATES Document ID: 1K1201493

Availability: ISIS, NotSIR
Major System: ENGINE
Current Language: English
Other Languages: NONE
Viewed: 199

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Please refer to the change log text box below for recent changes to this article:

Revision: 0
Created: 41312024
Last Modified: 5/22/2024
Author: Nick Zipadelli

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(05/22/2024 - Initial Article Release.

Description

The purpose of this article is to provide updated repair guidelines for the engine oil pan leak on all 8.8L gasoline and LPG engines. Engine oil
can leak from the rear of the engine oil pan due to an excessive gap in the sealing area between the engine oil pan and the engine block.

Symptoms

Diagnostic Trouble Codes & Dashboard Indicator Lights:

DTC/Light Description

No Faults or Warning Lights None

Customer Observations or Concerns:

© Engine oil is on the lower oil pan, transmission, and bell housing inspection plate.

© Engine oil leak from the rear main seal area.
* The smell of burning engine oil.

Special Tools / Software

Tool Description Tool Number Comments

Instructions

Not Applicable

Service Parts Information

Kit Description Part Number Quantity Required Notes

RTV Silicon Rubber 1830858C1 1
Engine Oil Pan Gasket 1
Diagnostic Steps
Step] Action Decision
DIAGNOSTIC: Yes: Confirm the engine does not have excessive

Confirm there are no other engine oil leaks that
need diagnosing.

YES/NO QUESTION?

Are there multiple engine oil leaks from the
engine?

blow-by or the PCV system is restricted. Follow PSI
diagnostics to find the root cause of the
condition.

No: Go to step 2

Step

Action

Decision

DIAGNOSTIC:

Perform a visual inspection of the intake valley
plate and confirm it is not leaking causing a false
engine oil pan leak. See Figure 1 for an example
of an intake valley plate leak.

**NOTE** The intake manifold DOES NOT need
to be removed to inspect the engine valley plate
for an oil leak.

YES/NO QUESTION?

Is the engine valley plate leaking engine oil?

Yes: Repair engine oil leak at the valley plate.
Clean the engine and retest for engine oil leaks.

No: Go to step 3

Figure 1

Step

Action

Decision

DIAGNOSTIC:

Confirm that the engine oil cooler, lines, and
fittings are not leaking.

Yes: Repair engine oil cooler leaks, clean, and
then retest.

3
YES/NO QUESTION?
No: Go to step 4.
Are there any engine oil leaks from the engine oil
cooler area?
Step] Action Decision
DIAGNOSTIC: Yes: Repair engine oil dipstick tube leak. Confirm
that the correct part number dipstick tube is
Confirm that the engine oil dipstick tube is not _ installed per that style of engine oil pan. (front
leaking. sump, flat bottom oil pan rear sump). Clean the
4 area of oil and debris then retest for concern.
YES/NO QUESTION?
No: Go to step 5.
Is the engine oil dipstick tube leaking?
Step] Action Decision
DIAGNOSTIC: Yes: Repair the front crankshaft seal outlined in
the PSI 8.8L service manual, then retest for oil
Confirm that the front crankshaft seal is not leak
leaking. .
5

YES/NO QUESTION?

Is the front crankshaft seal leaking?

No: Go to step 6.

Step] Action Decision

DIAGNOSTIC: Yes: Repair rear main seal, clean then retest.

Remove the bell housing inspection plate. Inspect
for leaking rear main seal using a boroscope or
similar tool.

No: Go to step 7.
YES/NO QUESTION?

Is the rear main seal leaking?

Step] Action Decision

DIAGNOSTIC:

Yes: Repair the engine oil pan with the procedure

Confirm that anaerobic sealant was not used 7 7 . p . r
outlined in the repair section of this article.

when the original oil pan was installed. Please see
attached figure 2 below.

***NOTE*** The transmission may need to be
removed to better inspect for a leak. Verify with a
boroscope that the engine oil leak is present
inside the bell housing.

No: Go to step 8.
YES/NO QUESTION?

Was anaerobic sealant used with the factory
engine oil pan installation?

Figure 2 |

Anaerobic
Sealant used
Sr gery + . tihematn
OP euyec cad kee Manes cap to block
joint

* Some may be reported as rear or front crank seal leaks

Cer teat

CR nes Ree ay ec RUN ALA Url ace lla
Rls

* Two different sealers do not adhere onto each other causing leaks

RTV sealant
used on oil pan
seal

Step] Action Decision

DIAGNOSTIC: Yes: Repair the engine oil pan with the procedure
outlined below.
Confirm that the engine oil pan is leaking.

YES/NO QUESTION?
No: Clean and retest for engine oil leak.

Is the engine oil pan leaking?

Repair Step(s)

WARNING! To prevent property damage, personal injury, and / or death, park vehicle on a hard,
flat surface, turn the engine off, set the parking brake, and install wheel chocks to prevent the
vehicle from moving in either direction.

WARNING! To prevent property damage, personal injury, and / or death, if the vehicle must be
raised, do not work under the vehicle supported only by jacks. Jacks can slip or fall over.

WARNING! To prevent personal injury and / or death, always wear safe eye protection when
performing vehicle maintenance.

WARNINGT To prevent property damage, personal injury, and / or death, keep flames or sparks
away from vehicle and do not smoke while servicing the vehicle’s batteries. Batteries expel
explosive gases.

'WARNINGT To prevent property damage, personal injury, and / or death, remove the ground
cable from the negative terminal of the battery box before disconnecting any electrical
components. Always connect the ground cable last.

Pr

Remove the engine oil pan assembly.
1. Be sure to clean all oil, RTV, and debris from the engine block and oil pan.
. Inspect for leaks at the corners of the rear main cap
1. If a leak is present, remove the main cap, apply the correct amount of RTV, then torque to specification.
1. *NOTE* Rear main bolts are not torque-to-yield (TTY) and can be reused.
. Install the oil pan with a new engine oil pan gasket.
1. Do NOT apply RTV yet.
2. Torque the engine oil pan fasteners to 10Ib-ft
. Determine the oil pan gap.
1. Using feeler gauges, measure the gap between the oil pan gasket and the rear main bearing cap. (Figure 3)
1. **NOTE* If no gap is present, do not install any additional cork gasket. Proceed with installing the oil pan per the service manual.
. Remove oil pan.
Using the measurement from step 4, determine which thickness gasket is needed. (1/8in or 1/16in.)
1. Cut a strip of 1/8in or 1/16in cork gasket that fits along the rear main cap (Figure 4)
2. Apply a Navistar-approved RTV to both sides of the cork gasket, then allow the RTV to become slightly tacky before installing it.
Apply RTV to the corners of the engine oil pan and rear main cap mating surfaces, (See service manual for application locations.)
1. Allow RTV to become slightly tacky before installing the engine oil pan.
Apply the RTV-coated cork gasket to the rear main cap (Figure 3)
. Install and torque the oil pan as described in the PSI 8.8L service manual. (The link to the manual is below)

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Figure 3

Figure 4 Cork installed with RTV on rear main bearing cap