I have a 1999 International 9900i with a Cummins.
The other day it started cutting out in high gear and blowing black smoke. It feels like the motor is trying to jump right out of the truck as soon as you get it up over 30lbs of boost pressure.
As long as you are not trying to get power out of the truck it runs fine, it just acts up when you are putting the fuel to it.
The first time I had an issue similar to this a fuel filter fixed it, but not this time. I put it in the shop and after 2 days they cannot figure it out.
I had 2 valves out of adjustment that they fixed, then worked on the fuel system bypassing everything, but this did not help. Then we checked the air system, making sure all the boots were good,
there is a pin sized hole in my air charger cooler, but they say that that should not be causing this issue. Also the fuel pump is working fine.
Recently I had to replace one injector, but the truck has been running great since then.
Does anyone have any ideas???? I am desperate.

 

Couple questions is the Turbo Wastegated and also you are over fueling if it is blowing black meaning your not getting enough air to it. Forget looking at the Fuel system look at your Air Intake System start with Air Filters see if they are Plugged check that Plumbing out be amazed what can into our Intakes plumbing. I have also seen it literally Collapse upon itself under vac pressure.

 

Like Ironeagle said, check the air filters first. If that doesn't solve your problem, you might find a mechanic who can connect to your ECM. That might help locate the problem. I usually associate black smoke with fuel. But, if you are not getting enough air, performance can be greatly impaired.

 

Based upon what you've described, it sounds like your inextricant disseminating gaunkulator is hyperfluggenating.

 

EGR valve maybe?

Could be fuel lines collapsing on the inside from old age

 

I don't believe 99 truck has an EGR. Black smoke usually signals air to air leak, or turbo problem...

 

Easy for you to say.

 

Hi,

To eliminate the charge air cooler from your problems, there is a company that manufacture diesel engine charge air coolers, you should try Vestas aircoil A/S in Denmark (www.vestas-aircoil.com)


Maybe they can advise.