Other than several niggles in my XUV500/W6/2011, I have been facing one frequent issue, that is of unreliable headlights.
About 2 weeks back, during night driving in rains, the headlamps (both low and high beams, simultaneously) blinked some 4 times at random in 2 minutes, and restored to normal afterwards. Next couple of days, headlamps functioned perfectly normal. It happened again last week, blinked a few times in a short duration, and later the headlights suddenly went off. No way to turn them on. Tried shutting off the engine, lock unlock (some old niggles on error lights on dash, music system malfunctioning etc, still need this treatment, especially during rains and high humidity). But this procedure did not help.
I noticed that parking light worked properly, but not the low/high beams, nor the 'pass' high beam. Surprisingly, putting the headlights in Auto mode made the low-beam work fine. Drove back home.
Next day, everything was normal and I started traveling during day time, but with keen observation (turning on low-beam during rains). Suddenly, after traveling some 6-7 kms, I realized the headlamps are not working anymore. Low-beam is always off in auto mode during day.
I strongly suspected the combination switch to be the culprit. However, just to ensure it is indeed the problem, I drive back home, checked all bulbs, fuses, relays, battery, visible / scent of any loose connections/cable burning, any cable cuts (rats etc) and everything seemed fine.
I also recalled, about a month back, after parking the car at night on one Saturday (I didnt drive on the next two days, ), by Tuesday noon, the battery had completely drained (2.8 Volt total). This battery is brand new (just a couple of months), Amaron maintenance free. I remember switching off all lights, including cabin lights, parking lights on Sunday night, and our watchman also did not complain of any lights remaining on that night or the next. Did the combi switch turn on any lights or gadgets at night automatically? Again this led to stronger belief that the combination switch is indeed the culprit. The current drawn must have been significant to discharge a 90AH battery in 2 days. Anyways, got the battery checked and charged from a professional, and the battery was not at fault. I checked everything possible, including idle current drawn in locked condition, everything seemed normal. The battery problem did not occur again. It is still a mystery, what made the battery go so low.
Anyways, I consulted the service advisors at NBS Sewri and Harekrishan Turbhe of the headlamp issue and asked if they have the combination switch is in stock. It was not available with either of them. One said cost is 6000, other said 4600. Both asked me to come to workshop for vehicle checkup before the workshop can conclude that the Combi Switch is defective. I told them that I will visit workshop when the part is available, as NBS especially far from my home.
Since the headlight is critical and did not want to take any risks, I went to a local (but claiming to be experienced, known) electrician. I demonstrated to him that the headlamps (low-beam) works fine in Auto mode, but doesnt work in manual mode and that high beam doesnt work at all. He still checked the relays, fuses, bulbs with his test lamp. Maybe he is trained to follow the same procedure and confirming things. Anyways, he said he did not suspect anything wrong with combi switch, but said there is a loose connection in the 24pin connector. He sprayed some WD40 to clean up the connector, reconnected it and said things are working. It worked for less than 3 minutes, and then headlamps went off again in manual mode.
Yesterday, I went to Harekrishan. As previously told by them, the part was not available with them. Still the service advisor asked the electrician to check what's wrong as the headlamps are still nor working properly. The electrician, within a few seconds, by just turning the switch concluded that the switch is defective. No electrical tests or checking any connectors, fuses, wires etc. He said the switch is not latching like normal. I told him that the mechanical feel is exactly same since the time the switch was last replaced by Mahindra under warranty. Anyways, I trusted his instinct, as he was more experienced. New replacement switch was not available, and would take atleast 8 days. I still spoke to the store manager, and he said he will check again. After checking his computer, he located one corrugated box with part name Combination Switch, but the contents were loosely packed, actually bubble wrapped. The switch looked used/old and the date of manufacture did not match either with the box. Mechanical feel was bad too, bit too inconsistent, softish, and dust and some whitish thing growing on the stem (like fungus). So I decided to reject the part and rather wait for fresh one.
It is important for me to state that Mahindra had replaced the combi switch twice in the past, under warranty. This is the third switch. How can this switch be so unreliable?
Secondly, I have had incidents in past of occasional blinking (some 5 times in last 4 years) on long duration expressway drives, I always though it may be some some bird or flying paper etc may have crossed the headlamp beams, or could be protection mechanism or software bug as the problem could never be reproduced at the workshop nor at home. It was never 4-5 times blinking in 2 minutes in city as it happened recently. In past, I got evetrthing tested - battery, terminals, bulbs, connectors, alternator, wiring etc.
Somehow, I have lost trust in the combination switch and want to have an additional parallel switch that could keep the headlights ON when I need, especially driving on highways, even if I replace the switch with a brand new.
Is there any way to know which of the pin numbers or associated colored wires in the connector are related to (a) Power (b) Low beam (c) High Beam, (d) Parking lights (e) Fog lights?
If anyone can share the pinout for the XUV500 combination switch here or a direct message, it save me some time and effort in reverse engineering.
Thanks so much in advance.
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