Devas are 'busy' in their Swarglok (heaven). Technology has crossed the boundaries of earth and even non-mortal devas had become techno-geeks. They converse in Hinglish. Meanwhile, a terrific war is being fought between the Devas and the Asuras. In this war, Lord Vishnu slices the demon Rahuketu into two parts through his stomach. His collapse invokes the Guru of Asuras, Guru Shukracharya and he comes forward to battle with Lord Vishnu. He also slices a large snake named Kaladansha into two parts. Lord Vishnu gains the upper hand in the war and throws Shukracharya into space. Shukracharya announces a prophecy throughout the Universe warning Lord Vishnu that the same humans whom he is protecting, in Kali Yuga, will themselves become very cruel than even demons, and a day will come when their cruelty will give rise to the greatest demon of the Universe which will engulf the whole humankind. Shukracharya then transforms himself into Planet Shukra or Venus and it becomes the home of demons. Later he joins Rahuketu's sliced body with that of Kaladansh's tail and vice versa. This gives rise to two demons Rahu and Ketu. Shukracharya declares that as long as his Sarpdand i.e. Snake Wand lives, the demons will remain powerful.
Hanuman, who has just returned to heaven after completing his task on earth, is bored. He sees a village boy named Minku, who is bullied by his classmates. He decides to help him, not as a God or an invisible force but as a human. He then asks Lord Brahma to allow him to take birth as a human being. Brahma allows but keeps 5 conditions that Hanuman agrees to accept. He appears on earth in a village named Bajrangpur from a priest and his wife as a human baby. What makes the reincarnated Hanuman different from other humans is that he has a tail and a huge appetite. The baby is named "Maruti" by his mother. One night, when the priest was going back to his home, he was chased by some thugs, kidnapped, and then thrown inside a blockage. After Maruti is three months old, he is admitted to the same school where the boy he wanted to help studies and befriends him. Thereafter, he teaches a lesson to Tunnu and Tanki, his bully classmates, the one-eyed criminal, and his gang.
Meanwhile, on planet Shukra, there is a fight between Rahu and Ketu and accidentally the Sarpdand comes to Earth. Danavs come to Earth to search for it but they have to face Maruti. Maruti easily defeats Rahu and Ketu with the help of his army of monkeys that came to help him to get free from the hands of culprits (who caught him because he stole the mangoes from his garden). To defeat Rahu and Ketu, Narada must remind Maruti that he is Hanuman. After Narada and Maruti meet, Maruti is reminded that he can turn to Hanuman as per his will. Maruti then turns to the more powerful Hanuman, with his godly powers. He still has the appearance of a child but looks like the child Hanuman, the appearance from the film's predecessor. Then a monster made of polythene and other non-biodegradable waste appears from a volcano that was said to have formed when Sarpdand merged with the Kamandal thrown by Shukracharya which coincidentally fell into the volcano in Bajrangpur. The monsters keep on swallowing the villagers of Bajrangpur. After struggling to stop the monster, Hanuman asked for help from God Ram. God Ram then said that when a blockage, which is seen in the end, is cleared then the monster (mainly made of plastic and other waste thrown by humans) will finish up. Hanuman did what Ram said, and the monster was defeated. Finally, Hanuman said his farewells to his family and friends and left Bajrangpur.
A spin-off series named The New Adventures of Hanuman was produced and aired on Pogo TV and Cartoon Network India. The series has some differences compared to the movie, such as Maruti staying in Bajrangpur instead of leaving it and several new characters. Maruti is also required to use a mace locket to turn into Hanuman.[4]
In the mobile game space, Jump Games announced a two-year deal with Percept Pictures for the creation and distribution of Hanuman Returns mobile games, at a launch event in Mumbai that featured film Director, David Dhawan.[5]
On the film's 12th anniversary, Director Anurag Kashyap said that Return of Hanuman was a 'terrible film' and that he was 'incapable of doing animation'. It is the only animation film he has ever made.[6] Nobody attended it.Anurag Kashyap was right.The movie was a disaster at the box office. His words proved correct but it still aired on television channels like SET Max, Pogo, Cartoon Network, and Star Gold. It was also dubbed in English and Bengali under the same title.
