Hey Guys:
I just rebuilt my 2002 5.9L that blew the #3 connecting rod bearing. I did a full lower rebuild and replaced everything except the cam. I honed the block and used standard rings. I ground the valves and replaced the valve seals and springs. Did a good break-in using Royal Purple break-in oil. After 3 oil changes (at 500 & 1000 & 1800 miles) I took a 1400 mile ride to Nashville then to North Carolina. When I got there I checked the oil and was 2 1/2 quarts low. When I got back to New York & changed the oil again I was 2 quarts low. I have no leaks and not blowing any smoke. Any ideas???

 

Did you check your bores for being round, or tapered? Properly align ring gaps? (as it, not all in a line..... )

 

Ring gaps were all good when I seated the rings. Never occurred to me to check the bore.