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Discussion Starter · #1 ·
I have 2.2 in my GLHT that was rebuilt 20k miles ago. We melted #1 piston, which dropped the compression from 125 to 90. We threw in new pistons and rings, and I have 10-15 easy miles on it since getting it back together. Compression is now 118-125-125-125 (was 125x4 before meltdown). I expect the 118 is due to some unusual/eneven glazing I noticed where #1 melted. The thing smokes like wild now though, mostly grey, tint of blue sometimes. It smokes pretty well constantly; far, far worse than it did with the melted piston. There is what appears to be oil in the tailpipe as well. There is no blow-by either. I can only assume this relates to the oil control rings or expander? Anyone run into this before? I am going to try hammering on it to see if they seat, but wanted to see if anyone else has been down this road. I've never had a rebuild smoke before!

I originally thought it must be the turbo, but we replaced it with what was believed to be a good one (worked when I removed it). There is no oil in the turbo hoses or intercooler. I even disconnected the oil feed to the turbo (blocked the turbine also) and dropped the downpipe, and still it smokes, so not the turbo I guess! I poked at the stem seals and the are still soft and appear to be well seated. PCV is stock TII airbox and plumbing.
 

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I have 2.2 in my GLHT that was rebuilt 20k miles ago. We melted #1 piston, which dropped the compression from 125 to 90. We threw in new pistons and rings, and I have 10-15 easy miles on it since getting it back together. Compression is now 118-125-125-125 (was 125x4 before meltdown). I expect the 118 is due to some unusual/eneven glazing I noticed where #1 melted. The thing smokes like wild now though, mostly grey, tint of blue sometimes. It smokes pretty well constantly; far, far worse than it did with the melted piston. There is what appears to be oil in the tailpipe as well. There is no blow-by either. I can only assume this relates to the oil control rings or expander? Anyone run into this before? I am going to try hammering on it to see if they seat, but wanted to see if anyone else has been down this road. I've never had a rebuild smoke before!

I originally thought it must be the turbo, but we replaced it with what was believed to be a good one (worked when I removed it). There is no oil in the turbo hoses or intercooler. I even disconnected the oil feed to the turbo (blocked the turbine also) and dropped the downpipe, and still it smokes, so not the turbo I guess! I poked at the stem seals and the are still soft and appear to be well seated. PCV is stock TII airbox and plumbing.
probably damaged an oil ring on assembly, didn't properly install oil ring/expander, didn't deglaze cylinder wall properly, these are all causes of oil smoke with good compression
 

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Pull it back apart and do a light hone on that cylinder and make sure to properly stagger your ring gaps.
 

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+1

You should have honed out that cylinder after melting that piston, especially if you noticed glazing. Take it apart and get a cylinder hone from parts store and try again. Good luck!
 

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Discussion Starter · #5 ·
Thanks for the input; but you all must be wrong. It *must* be something that does not involve my making assembly mistakes or exercising poor judgment.
 

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How do the spark plugs look? If you did not deglaze, I imagine the new rings will have a tought time sealing. No worries, do the job again and all will be good.
 

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Discussion Starter · #7 ·
The plugs were dark, 2 of them dry, 2 of them seemed damp, but also smelled a bit of fuel. I only have about 15 easy miles on it, so I am going to try the HI-PSI break-in run to see if they seat or not. If not, I will try the hone. The engine still showed plenty of crosshatch from the previous rebuild (~20k miles) so I thought I might get lucky, and I think I did, but only on 50% of the cylinders. doh.
 
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