Originally Posted By: A_Harman
Interesting variety of answers on this thread.
Years of experience with my riding mower eventually led me to consider the ADD mark to represent FULL. While mowing my property, the engine would get oil in the cylinder and put out a large plume of white smoke if I was heading downhill for too long. I consider 1/8" below ADD to be the practical low level.
The Camaro I used to top up if it got halfway between FULL and ADD. Unless I was at a track day, where I would overfill 1/2-quart above ADD and check the oil before every session. But lately, since the oil consumption has gotten to 1 quart per 2000 miles, I just let it get down to ADD, then put in a full quart.
On the Dodge, I found that it used less oil if I kept the level 1 quart from FULL. Then I would just add 1 quart if the level got to ADD. But since I recently had the oil pan gasket replaced, I think I'll go back to filling it all the way up, then add when it gets a quart low.
I have done dyno tests at work where we ran as much as 4 quarts low on an 8-quart sump, and the engine still had stable oil pressure when running on a low-speed test cycle. (Strictly in the name of science, of course.)
This is by far the best summary.
The mark on the dipstick is just a worst case guestimate by the mfg. It is safe to run almost any engine far below the full mark in almost all cases.
When I was building engines regularly I would test fit the oil pan and mark the max level on the dipsticks (wet sump engines) based on keeping the oil level below the crank and windage screen and allowing for 1g (45deg) oil angles. The min oil level could have been 3 to 4 inches lower and still had good capacity and no suction issues. However, everybody expects to see a low mark about an inch or less lower, so I just marked there.
Everybody has these crazy ideas engines are scientifically engineered. That's pretty much non-sense. Engines are designed for the typical idiot operator and warranty concerns.