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Excessive Black Smoke

WARNING: This page is about a different car, the 1995 Ford RV Cutaway, 1995 Ford Econoline, 1995 Ford Cutaway, and 1995 Ford Club Wagon. However, it is still accessible from the selected car via links, so may be relevant.
  1. If smoke occurs under light load and/or low altitude, go to next step. If smoke occurs under heavy load, this is normal when going up steep grades, pulling a trailer, maximum load, maximum acceleration or at high altitudes.
  2. Visually inspect exhaust system for dents or kinks which could cause restriction. If exhaust system is okay, go to next step. If dents, kinks or restriction is found, repair or replace exhaust system as necessary. If problem still exists, go to next step.
  3. Perform CHECK AIR INTAKE RESTRICTION  test under ENGINE PERFORMANCE DIAGNOSIS. If air intake restriction check is okay, go to next step. If air intake restriction is found, replace air filter element and/or repair system and repeat this test.
  4. Check and/or adjust dynamic injection pump timing. See DYNAMIC TIMING in ADJUSTMENTS - 7.3L DIESEL article. If injection pump timing and idle speed is correct, go to next step.
  5. Check injection nozzle line(s) for kinks or restrictions. Replace any line that is kinked or restricted. Remove injection nozzles from engine and test. See INJECTION NOZZLE TESTING  under COMPONENT TESTS. Replace any nozzle that does not pass test. If lines and nozzles are okay, replace injection pump.
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