All diesels smoke heavily when accelerating hard, its just what they do. The old endura diesel engine were known for blocking the EGR valve with soot, this will cause smoke on acceleration, however I have not heard of a problem with a modern ford common rail diesel doing this. More than likely your being a bit paranoid about it!

As for remapping, No it isn't cheap however diesels respond very well to remapping and you will also see increased fuel economy.

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