My Red Highway King: XUV500 W8 Initial Ownership Review


Thread Starter #332
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DIY changing diesel filter in my XUV500

Buoyed by the successful DIY of changing diesel filter in my Tata Nexon, as demonstrated Here ,attempted the similar DIY in my XUV. Here it as much more tough, as lot of parts had to be removed to access the fuel filter.
It need removal of
1.Complete Air filter assembly,
2.Battery ,which is very heavy to pull out in XUV(95V )
3.MAF sensors. Sensors for the fuel lines, sensors for fuel temperature (I never knew it existed, until I handled it. XUV is filled with sensors and sensors all over!!
Unlike Nexon here in XUV the whole filter assembly is a single unit. You cannot simply change the filter cartridge, and you have to change the whole spin-on type diesel filter.



Brand is Bosch and made in Spain
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This is the hand priming pump for the fuel filter. This hand priming pump is also Bosch make
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Diesel input and output line to the common rail. Blue arrow points to the output line.
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All the sensors and battery and air filter assembly removed
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Very happy to see that this red coloured battery bracket has no rust whatsoever. Usually acid spillage destroys it in 8 years.
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Old filter had lot of diesel inside. I had no intention to waste it. I drained it and collected the diesel for DIY etc.
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New and old filter side by side
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Water in the fuel sensor has to be tightened at the base of diesel filter.
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This DIY took more effort and more time as it was difficult for me to reach the deep end of engine bay, as XUV engine bay is longer and wider and filter is just at the farthermost end near the firewall, below the windshield.
There is a nut provided just for the hand priming pump. No need to detach the fuel lines. As soon as you loosen the bolt > press the pump > fuel starts sputtering from the nut > close the nut > you are good to go.
 
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Thread Starter #333
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continued:

There is no CEL as of now. Will drive it more and give the feedback. XUV is behaving just as before, no difference whatsoever after the DIY.
This is the first time that I have ventured so deep in my DIY, and have removed so many sensors and parts and wires and cables to complete this DIY. Feel elated and very satisfied that by Gods grace I could do it all by myself without ruining it (which I feared). Like everybody here I love my cars and the last thing I want is to ruin them.
This is not my profession. Far from it . I haven't been trained in it. I don't have any engineering qualification. Its just my hobby, and I do it because it gives me happiness. Will keep on doing it. And posting it too.
 
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This is not my profession. Far from it . I haven't been trained in it. I don't have any engineering qualification. Its just my hobby, and I do it because it gives me happiness. Will keep on doing it. And posting it too.
Trained or not trained, this just shows how much love you have for your cars. By looking at all your DIY posts, I can see you are doing a far better job than most of the trained guys do.
 
Thread Starter #337
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superb work doc saab !
Thank you for your compliment.
any special tool used for removal of filters ?
And double thank you for pointing this thing out ,which I forgot to post.



Most diesel filters have water in the fuel sensor right at the bottom of the filter. It doesn't matter whether its a cartridge type of unit (like in Nexon )or spin-on type filter (like in XUV500). That makes it very difficult to use conventional engine oil filter socket type openers.
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The ring type spanners fit perfectly but there is no space at all to rotate the filter because of such a loooong handle of the opener.
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This type of opener works perfectly here. I don't like to use it ever on oil filters as such because it has a tendency of denting them and putting them out of shape.
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All the rotational force is applied at a pivotal point. Because that is actually the leverage point. That causes denting at the filter wall.
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Has anyone noticed that the hole pattern in both the filters is completely different. Old filter had round holes while new one has oval. This despite of matching the part no. and all.
I have been told that this will make no difference in functioning of the filter.

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The wall also have different groove pattern in both. Just lets hope I haven't been handed over a Scorpio or a Xylo filter. Although the fitment is perfect on the mounting point.
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Sirji the size of the opening orifice can influence the pressure of flow if i am not mistaken .Please use the right type and don't buy the salesmans" chalta hain " because if something happens you will end up paying for repairs
 
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If part number is same, nothing to worry of. They won't mix up part numbers for model specific parts. These can be improvised parts. Indian brands have been doing this for ages. Bigger holes for better flow.
 
Thread Starter #340
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If part number is same, nothing to worry of. They won't mix up part numbers for model specific parts. These can be improvised parts. Indian brands have been doing this for ages. Bigger holes for better flow.
I agree with you. The side holes are for dirty fuel going in. The center hole is for clean fuel coming out. So there should be no worry for pressure changes. Had it been vise versa the pressure to common rail would have changed.


Here now the fuel coming from the tank will go in more easily that's all.

(Picture credits to engine hub.com)
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Thread Starter #343
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Cracked Holding clip for diesel fuel intake pipe

In my routine inspection I found out that the Holding clip for diesel fuel intake pipe has cracked and on subsequent inspections it got broken into 2 separate pieces. It was due to age related plastic degeneration. There were no symptoms. No fuel leakage, nothing. But I was worried that fuel intake pipe might hang too low with the clip holding it in place already broken into 2. It will then start rubbing with the rear left tyre.
I started searching for this clip in the Mahindra ASS in my city. I was very surprised to find out that it was nowhere to be found. Clip cost is only 50 Rs, but its very difficult to get hold of.
Finally I purchased the clip last week. And went about changing it.


Pics speak for themselves.


Holding clip for diesel fuel intake pipe
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this is the second Holding clip for diesel fuel intake pipe
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After washing and cleaning the clip area
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Old and New Holding clip for diesel fuel intake pipe
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cracked Holding clip for diesel fuel intake pipe
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New Holding clip for diesel fuel intake pipe installed
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Finally cleaned the alloys and area around the wheel well
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Note the shiny bolts. No amount of cleaning did work here as there were scoring marks on them. I had to change them because MASS overtightened them with pneumatic wrench spoiling the grooves. These in the pics are actually new.
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This is the broken clip. And the part number for it.
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