Whistling sound coming from my XUV500's engine: How I saved big bucks

The Mahindra service centre told me that a new turbo would cost around Rs 50,000 but I got the problem solved by spending just Rs 6,000.

BHPian RajivNarvekar recently shared this with other enthusiasts.

Dear friends,

I need some advice, please help.

I bought my XUV5OO W8 in July 2014 from Sahyadri Motors, Pune. I have had a fantastic run so far and have clocked 154000+ km. I have been regularly getting my XUV serviced.

Last week on my return from Bangalore to Pune, I started getting a whistling sound from my engine. I noticed it when I had slowed down at a toll booth. As I moved from 1st to 2nd to 3rd gear, I thought there was an ambulance 9-10 cars behind me. I slowed down but obviously, there was no ambulance.

This noise comes when the RPM is above 1700-1800 rpm and is probably caused when the turbo kicks in. On reaching Pune, I went to my trusted mechanic. We checked the following:

• Leakage in radiator hose pipes - No problem
• Cleaned the "EGR valves" of carbon - no problem
• Leakages in radiator - no problem

The whistling sound has been around since day 1. It was very light for the last eight years and I "enjoyed" the feel of a race car. None of the passengers would notice it unless I pointed this to them.

Now my mechanic is suggesting I go to the service center for turbocharger replacement. I called my regular service advisor and he has suggested it would cost around 50K. I have not yet taken the car to the service center.

When I asked my service advisor about faulty vacuum modulators / regulators he said based on his past experience it could be the turbo.

I don't have:

• A check engine warning
• Black / blue / grey smoke
• Loss in pick up

I just have an easily noticeable whistling sound.

I have so far spent money only on tires, brake lining and discs, white LED headlights, replaced the silver box with an android player, clutch plates, and front and back suspension. No problem on the engine side...

I have no intention to sell the XUV, it has been a dear family member. Will use it till it can be used.

What should I check to really replace the turbo and incur a cost of about 50k?

Many thanks in anticipation

Update

Once I realized that the service centre was trying to replace the Turbo without a valid reason, I did the following:

• I looked up which Turbo was fitted in my XUV5OO. It was from Turbo Energy Limited. I looked up the exact part number and called their dealer in Pune. I spoke to Clean-O-Diesel Services India (P) Ltd. Their head Mr Vijay was very helpful. He asked me a lot of questions and then suggested that I take my XUV to a mechanic. Based on my location he suggested a mechanic, Raju Pansare.
• Raju's garage repairs only M&M Scorpios and XUVs. Raju was very polite and we had a call with Vijay from TEL. After 15 minutes of diagnostics, we all concluded that the exhaust metallic packing from the Turbo was the culprit. The packing cost was about Rs 3500. I left the vehicle with Raju.
• The next day Raju took the turbo to Vijay's service centre and made some minor adjustments for a fee of Rs 2500. He later fitted the Turbo and the whistling sound disappeared. By spending Rs 6000 my problem was resolved as opposed to the Rs 55000 suggested by the service centre.
• I took the vehicle for a long drive of about 50km and the XUV was back to normal. I asked Raju if it needed any more tweaking. He then told me that the fan belt would need to be replaced, the shock absorbers that I had got fitted were "not OEM" and that my engine oil needed to be replaced.
• He said, he did not want to inflate my bill, but because I did a lot of long-distance driving, he suggested that I replace the fan belt. He also showed me the "kich kich kich" sound that was coming from the fan belt. I said no problem as I always believe in the adage, "Trust everybody till they prove themselves to be untrustworthy".
• Just to validate the repairs, I reached out to my engineering classmate who works in the M&M Chakan plant. He arranged a call with an engineer who specialized in engine testing. The engineer on a WhatsApp video call confirmed that all is well with my turbo and the engine and the fan belt would need a replacement.
• All this took 4 days. The belt replacement cost me Rs 13500. I also got the vehicle service with engine oil replacement. At the end of the 4th day, I paid him Rs 25000 and now my vehicle is as good as new. I will strongly recommend Raju Pansare for M&M vehicles especially older out-of-warranty vehicles.
• The plan now is to drive till my XUV completes 170k km and assess the overall fitness.

My closing thoughts

It is important to get a 2nd or even 3rd opinion on any repairs that cost more than Rs 20k. It is not the amount but the feeling that you are getting cheated that infuriates me.

My XUV5OO will complete 10 years in July 2024. When I told my M&M engineering classmate that I am considering buying another SUV he told me that a refreshed XUV 700 will be available by Jul 2024. I am thinking about which SUV to buy next and my son is eyeing the current XUV500. But that is for another post.

Thank you friends for your support.

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