After a long struggle, The beast came back to my Porch. Here is my experience with this Mess, Point wise.
1> Final Diagnostic is that Turbo Boost pressure was too high. Normal Boost pressure is usually in the range of 1.1, But this happy chap was putting out 1.3. This is a strange case because Turbos usually loose pressure when there is a problem. Here it was overboosting.
2> The next step was to replace the Modulator. A Modulator is 3 plug electrical component that actuates the VGT Vanes (Hence boost). XUV uses electrical Actuator compared to Cable driven or Hydraulic in Some vehicles.
The Check error returned at 140 even with new Modulator, So my old Modulator was placed back and Order was logged for New Turbo. Turbo took about a week to arrive.
3> In the term of 5 years (XUV was launched in '11), The Service center- Aakash Motors Dhule said this was only the 2nd turbo failure reported
. Mahindra Turbos usually last 2~2.5 Lac Kms. They are only replaced when engine is reworked. Bolero Turbos usually last longest due to Low Rev- High Torque nature of the engine. There are been absolutely zero turbo failures reported in Bolero.
The 1st turbo failure case they had was due to a lady driver who drove her vehicle despite leaked Turbo Pipe (visually demonstrated by Heavy smoking and loss of performance).
So overall, this could be an oddball, One off case regarding Blown Turbo.
4> Mysteriously, They did not find anything wrong with the turbo on Physical inspection.
The Turbo was not starved of oil
There is no Play in bearings
There is no Deformity in Impeller.
I do follow idling procedure at crank & Shut down.
Vehicle is Mostly driven by Dad who hesitates to cross 90 KMPH.
The Old turbo has been sent to R&D center for dismantling & Inspection.
5> The test drive was carried in below manner-
50KMs-upto 130 KMPH
50KMs-Upto 165 KMPH
25KM- Dhule city.
Dhule to my House- 70Kms
With me- 10Kms
Overall, thats over 200KM of testing carried. Very thorough indeed. They sent (on my request) the technical manager along with the vehicle to my door step to keep tab on turbo & also explain me the diagnostic process.
They filled some diesel on the return journey as courtesy. Which was a nice gesture indeed.
6> The last service was carried at Nashik at some 60k Kms. Odo Now reads 60,900 KM.
7> The vehicle was delivered Scratch-less, Clean & neat- As I always like to be. I should really appreciate Mahindra on That. Nothing else was touched or messed up. My HU settings were not changed. Even small bits like paper, toll receipts, Cleaning cloth were in default place- Untouched. Thats a great thing!
They gave a courtesy Interior & Exterior cleaning before dispatch.
8> After the initial rest drive upto 125KMPH, The performance has returned. Its finally great to feel the beast alive again!