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Old 17th July 2017, 18:15   #136
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Default Re: Mahindra Xylo E8 (ABS):-Spacious, Feature-Packed, 8-Seater, Head-Turner Beast is Here

Hi friends,

My Vehicle: Xylo E6 (June-2010 model), current ODO = ~183000 KMs

Topic: Alternator issues, resolved.

This May'17, I was on a long road trip and this problem happened when OD was about ~177000 KMs.

Symptoms:
- bit delayed cranking, system reset just like when battery disconnected (DIS console readings were reset, HU settings reset);
- voltage drops, affecting electrical devices (AC, lights, horns, music system etc);
- battery not charging properly;

I had installed this Lighter Socket splitter & charger (link) it was showing voltage changes in real-time, and low-voltage resulted in blinking digits.

Very useful gadget, apart from multiplying your socket & USB points, you will know real-time about voltage changes when you start your regular tasks eg. mobile charging (low), horn, headlights, AC, power-window (worst), etc.
Standard voltage should be 12.5v on a vehicle not started, without running any device. On a running vehicle, the voltage should be ~14v, depending on how many devices are running.

Troubleshooting (identifying the real cause!):
When the voltage dropped, affecting the electrical devices to ill-perform, it was clear that problem was in electrical department, but where ?!

I really didnt doubt battery, as it was changed just a year back in April 2016 (link (Amaron batteries)) and just before leaving on this trip I had got the battery checked at my known shop, found it OK.
Still I did some tasks for peace of mind. Firstly, cleaned the terminals, inserted a small wire piece to get proper contact of terminals. Next, at a shop got the battery checked, one of cell was bit fuming, and battery was not showing fully charged. But technically, with such a long trip and daily long drive, I doubted any issue within battery for being low charged. I know, things can go wrong anytime, but still. Also, when the vehicle was running on good speed, as per me the electricals should have worked properly, but it didn't!


In all these 7 years, never did I touch the alternator (TVS-Lucas make OEM fitted), but I was somehow getting a feel that something was wrong within the alternator. Found a Bosch authorized shop, and explained the issue. The guys were really efficient, the battery was checked, and also the alternator cover was opened. The alternator was just kept mounting, no changes. From inside, the voltage regulator part was removed, and found that carbon brushes were totally worn-out. Voila, the problem was identified, and it wasn't really a big problem, and pretty pocket friendly too. These brushes, spring-mounted, keep rubbing (electrical contacts) on the coil underneath it, wound on the alternator. Over the years, these brushes can worn-out. I was told that new 'original' Lucas Regulator would cost around Rs.800, and I said OK to it.

However, the guy did a workaround (jugaad), and just soldered new brushes on the existing regulator, quote mere Rs.180. They informed me that new part was somehow misplaced in their shop, and may take time to search. The engineers and even owner were nice people, and they really help me in distress situation. The vehicle was now properly starting, but I was told to keep running the vehicle for 50+ KMs without any electrical devices (AC, music etc), and the battery will soon get properly charged. I asked if this workaround will really work, I was confidently replied that no issues with such solution. After running the vehicle for some time, I kept noticing the voltage on my gadget, and now it was all good. Finally I started the AC, and the cool air made us comfortable.

I completed my trip properly, without any issues, and also drove for few more days in local. But I didn't want to take any chance on above solution, and few days back got a new Voltage Regulator (Rs.700), and had it fixed. The earlier regulator is kept as spare for now. I still got the battery re-checked at my regular guy's place, it was all OK.

Attached file contains the pictures for explanation.

Suggestion: Like in my case, opening of voltage regulator on alternator takes just 5 minutes, it would be worth-while to check this part if your vehicle is older than 3-4 years.

regards,
Pranav
Attached Files
File Type: pdf alternator regulator (Xylo).pdf (1.80 MB, 182 views)
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Old 17th July 2017, 20:22   #137
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Default Re: Mahindra Xylo E8 (ABS):-Spacious, Feature-Packed, 8-Seater, Head-Turner Beast is Here

@pranav, jacs and the fellow Xylo owners
Hi guys,
Sharing a picture of Xylo I found on Xylo Facebook page just because its worth it.
Do you think that it has upsized tyres? Xylo definitely looks stunning in this picture.
I have read posts after posts but seems no one ever upsized the tyres on a Xylo. Even I am skeptical about it as it may impact negatively on the handling and suspension aspect of the vehicle, but 215/75 R15 looks too small for its size.
Attached Images
 

Last edited by wrongturn : 17th July 2017 at 20:25.
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Old 18th July 2017, 17:11   #138
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Default Re: Mahindra Xylo E8 (ABS):-Spacious, Feature-Packed, 8-Seater, Head-Turner Beast is Here

Quote:
Originally Posted by wrongturn View Post
@pranav, jacs and the fellow Xylo owners
Hi guys,
Sharing a picture of Xylo I found on Xylo Facebook page just because its worth it.
Do you think that it has upsized tyres? Xylo definitely looks stunning in this picture.
I have read posts after posts but seems no one ever upsized the tyres on a Xylo. Even I am skeptical about it as it may impact negatively on the handling and suspension aspect of the vehicle, but 215/75 R15 looks too small for its size.
Hi,
indeed a beautiful pic, Xylo is easily capable of all such (& more) terrains.

Looking at the pic, I think they are stock size tyres with stock alloys (H9 model ?). I suggest if you can connect with that user ("Firosh Aryadan") and query him directly, I saw he's on FB (sry, I dont have FB acct!!). As you also pointed, bigger tyres could negative effect on the handling & stability.

The initial Xylo batches, E series had more body roll ("boat-effect"), which was addressed to great extend in H series, major tweaks within in the suspension, and some minor changes in body. However, in general, Xylo has a higher Center of Gravity as compared to other SUV/MUV (eg. Scorpio, Bolero, Innova) and hence it may still have a slight roll. In my vehicle, I have noticed that even tyre pressure plays a big role in providing stability.
With a loaded vehicle, one will hardly feel such roll, and it keeps planted to road even on high speeds. Caution to be observed on high speeds, as it behaves differently on turns or while braking. Once you know the vehicle better, you can do too good with you

regards,
Pranav
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Old 18th July 2017, 19:03   #139
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Default Re: Mahindra Xylo E8 (ABS):-Spacious, Feature-Packed, 8-Seater, Head-Turner Beast is Here

Quote:
Originally Posted by pcpranav View Post
Hi,
indeed a beautiful pic, Xylo is easily capable of all such (& more) terrains.

Looking at the pic, I think they are stock size tyres with stock alloys (H9 model ?).

The initial Xylo batches, E series had more body roll ("boat-effect"),

regards,
Pranav
I am a proud owner of Xylo H4 ABS 2015. Its a very capable tourer indeed and I have taken it to some challenging terrains already.
Never had any complaints with the suspension setup or drivability or handling or power its a perfect package for the price, incredibly VFM.
IMHO these are not stock alloys and even if they are of size 15 still the sidewall of tyres look taller than the usual 215/75 R15 that comes as standard with Xylo. I am confident its an upsize because there was another pic which clearly showed wider tyres than usual.
The facebook pic of Xylo is from year 2012, and I left a message but got no response.
Thanks for the reply.

Regards
Abhishek
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Old 25th September 2017, 17:54   #140
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Default Mahindra Xylo replace Brake Switch & Clutch Switch

Hi friends,
allow me to share some 'different' updates, as the regular tasks are ongoing, and possibly not interesting !

Current ODO: ~187000 KMs

Since many days I had observed:
a) rear brake light used to stay ON, and soon I was able to pinpoint the exact cause
b) at low speeds, the vehicle used to judder and seemed like momentarily losing power, and suddenly waking-up to power. I was confident of the actual reason.


Bit tight schedules and some laziness, I prolonged attending the same. Last Friday I started bit early from office and went to nearby Mahindra workshop (G3 Nerul), purchased few parts : Brake Switch, Clutch Switch, 2 x pedal rubbers.

Regarding the pedal rubbers (clutch & brake pedals), they do wear-out, and its necessary to keep a watch. Without the rubber, your feet will slip on the metal pedal, and can cause accident. In the past, I have changed 2-3 times these rubbers, and I noticed that wear depends on few basic conditions: quality, usage of pedals, atmosphere, type of shoes, water/mud on rubber, fitting. Interestingly, in past twice I have purchased from a reputed dealer, costing me Rs.60 per rubber. Whereas this time from Mahindra Workshop (G3 Motors, Nerul) they charged me just Rs.20 per rubber. Its just a 2 min job to replace these pedal rubbers.


Brake Switch replacement:
Because of the push button on this switch gone kaput, even after releasing the brake pedal, many times the brake light used to stay ON. Twice I did apply WD40 spray on this push button, but it didn't help, and I had to randomly keep tapping the brake pedal to close the circuit. The light surely consumed unnecessary electrical power (I keep a watch on the voltmeter in my charger, nice device), but I believe such circuit would not really be giving "Brake-ON" input to ECU. However the good thing (built-in electrical design) is after shutdown & locking the vehicle, the brake light used to shutdown automatically.

OT: Just reminds of the "follow-me-home-headlight (what is that 'follow-me-home' headlight?)" feature in many vehicles, including mine, but I couldn't figure how to disable it.

The access to this switch could be bit tricky, otherwise replacing the switch is a small task. Gently detach the electrical connection. There is one nut fixed on the frame, and another nut needs to be tightened on the switch from back side. While fitting ensure that push button is completely pressed (to stop circuit) when pedal is kept released, accordingly the rear nut may need slight adjustment of tightening. Once switch is fixed, attach the electrical connector. Now check the brake light by pressing the brake pedal, and observe the play as needed.

Mahindra Xylo E8 (ABS):-Spacious, Feature-Packed, 8-Seater, Head-Turner Beast is Here-view-floor.jpg

Mahindra Xylo E8 (ABS):-Spacious, Feature-Packed, 8-Seater, Head-Turner Beast is Here-brake-switch-pressing-opr.jpg


Mahindra Xylo E8 (ABS):-Spacious, Feature-Packed, 8-Seater, Head-Turner Beast is Here-brake-switch-pressing.jpg


Mahindra Xylo E8 (ABS):-Spacious, Feature-Packed, 8-Seater, Head-Turner Beast is Here-brake-switch-old-new.jpg


Mahindra Xylo E8 (ABS):-Spacious, Feature-Packed, 8-Seater, Head-Turner Beast is Here-brake-switch.jpg


Found related article : https://www.yourmechanic.com/article...-spencer-cates

Xylo Brake Switch : Part Nu 0606DA0021N
http://www.mindadsl.com/product_deta...=S03028-000E00 (On my switches, I didnt find the company name inscribed)

Only for ref : Link-1 and Link-2


Clutch Switch replacement:
As wrote earlier, I was sure of problem due to kaput clutch switch. In the past, twice I have changed this switch.
some previous talks can be found HERE (Mahindra Xylo E8 (ABS):-Spacious, Feature-Packed, 8-Seater, Head-Turner Beast is Here)

However this time I actually found the rear nut to be loose, and it was not holding the switch properly. I simply adjusted the push button position and tightened the nut, didn't replace the switch yet. Its just a day yet, and I think the problem is solved! The working & adjustment of clutch switch can be easy to identify, by watching the "N" (Neutral) indicator in the MDI/DIS console.

Mahindra Xylo E8 (ABS):-Spacious, Feature-Packed, 8-Seater, Head-Turner Beast is Here-clutch-switch-pressing-opr.jpg

Mahindra Xylo E8 (ABS):-Spacious, Feature-Packed, 8-Seater, Head-Turner Beast is Here-clutch-mdi-status.jpg
Notice that I haven't removed the original protective film from this console display even after 7+ years/1.87 Lac KM :-)

Mahindra Xylo E8 (ABS):-Spacious, Feature-Packed, 8-Seater, Head-Turner Beast is Here-clutch-switch.jpg


Xylo Clutch Switch: Part Nu 0606DB0011N
http://www.mindadsl.com/product_deta...=S03032-000E00 (On my switches, I didn't find the company name inscribed)

Only for ref : Link-1 & Link-2


While I was trying to online locate the OEM for these switches, I came across a part "Clutch Pedal Position Sensor". I think maybe this part would be conveying something to ECU ?
http://www.mindadsl.com/products.php?p_id=2&sub_id=6 (shows part for XUV, Xylo, Scorpio). Only for ref : LINK

However, in my vehicle visibly I couldn't locate any such part, especially I also checked for any more electrical connector, but none. Maybe its specific to certain newer models (H series?) of Xylo ?



Did two more small tasks :
- cleaned the Cabin AC Filter (located behind the glove box) and AC blower motor (located under the glove box). As the dust particles get trapped in these parts, the AC performance decrease. I notice a drop in cooling and air flow every 30-40 days, and then get it cleaned. Surely the filter is clogged, and simple run under water is enough. I recall a LINK (Exhaustive DIY: Cabin AC Filter cleaning of the Ford Figo) by our colleague.


regards,
Pranav

Last edited by .anshuman : 26th September 2017 at 09:49. Reason: Added a line on request. Thanks
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