Yesterday, I drove my truck for the first time since early February. I was going to swap a 2.3 Lima from a 1996 truck that had supposedly rebuilt, but when I went to check the timing, I found that the crank bearings were severely galled. Unfortunately, I did not discover that until I had already pulled my factory 2.3 engine.
I decided at that point that I might as well tear down the factory engine that was consuming 1.5 - 2 quarts of oil per tank of gas. I found most of the valves covered in thick carbon, so I sent the head off to the machine shop to get rebuilt. Surprisingly, the block was in fantastic shape, but the piston rings were so carboned up that it was allowing the massive blowby. The cylinders were all within factory specs, so I proceeded to hone the cylinders and install new rings. After getting the head back from the machine shop and reassembling the engine, my buddy and I reinstalled everything two weekends ago. When we fired the engine, it ran great but smoked 10 times worse than before!
Much cursing and diagnostics followed for the next few hours. A compression test showed that we were in the low 40 psi range. So we pulled the engine, again!
Come to find out, the piston rings must have been mispackaged (purchased from NAPA). What was listed as a a 1.5mm, 1.5mm, 4mm ring kit was actually a 1.5mm, 1.5mm, 3mm ring kit, which allowed the massive blowby.
I re-ordered rings, this time from RockAuto, and they arrived last Thursday. We verified the correct oil control ring thickness, and I spent Saturday re-assembling the engine (again!). Sunday, we were back in the shop by 9 am and had the engine re-installed by noon. This time when I fired it, we had light smoke for the first 10 minutes of break in time before the rings fully seated. I then proceeded to drive the truck for half an hour around some hilly side roads, being sure to vary RPMs and speed to fully seat the rings.
It felt SO good to drive my truck again without a cloud of smoke behind me!
I know every nut, bolt, and fastener in my engine bay intimately well now, and I also know to double-check parts specs before proceeding.