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hi, had same problem twice with my 98 expert , first time it was heater control board(the slider sends a varying voltage thru the thin green wire at the motor plug, to a semi conductor encased in an ally heatsink when checking motor operation check thick red wire for 12v, and thin green for 1.5-4.5v, depnding on slider movement, and thick green for earth conn) , second fault was overheated conns both at motor conn and at relay(mine was bright green cased one behind glovebox), Terry
window wipers off remove trim and there is 10 mm nuts, remove them, remove speedo cluster and radio etc, there is 2 10mm bolts below each end in footwells at end bottom of dash, 1 bolt below your ash tray in front of gearstick, u got to get gear stick surround out.
email this guy at firstname.lastname@example.org he sells the carbon brushes new at only 5.99 a pair! Its fantastic and they work a treat. Why pay £300 when it will cost 5.99 to buy a new set of carbon brushes!!
Hi, I have a 2.0HDI Expert which was doing the exact same thing as yours, blowing thick black smoke, sluggish and loss of power on gradients, a hissing sound and surging. I replaced the air flow meter but that didn't help. I was told to replace the turbo but a turbo expoert told me not to as it would blow white smoke if it was faulty. I was then told to replace the injectors but a diagnostic test showed them to be functioning fine. I was then told to look at the intercooler which had thick sludge at the lower left pipe. I replaced it today - Sunday 12th July and it is now driving like a new van. It now pulls me up gradients with ease in 4th and 5th instead of having to drop gear to get to the top. I got a replacement from Euro Car Parts for £147 inc VAT. To tell if this is your problem, look through the gaps in the lower section of the bumper at what looks like the radiator and look for sludge over the inside of the bumper and all over the pipe where it joins the back of the radiator (intercooler). Also open the bonnet and look down behind the grille for the same sludge. Hope this sorts it for you. Barry, Newtownards, Northern Ireland.