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In the growing automobile world, every commercial vehicle manufacturer upgrades their product from their existing product to meet world market demand for high power engine with high torque, most fuel efficient, BS-IV and BS-V emission norms and less cost. In an Engine cylinder block and cylinder head are among the critical parts need to be modified to upgrade the existing engine platform. The VE4101 Engine is a massive 3.8 l 4 Cyl 16 valve engine based on the E483 4 cyl 8 valve engine, which is currently being mass produced in VECV, India. This engine cylinder block and cylinder head are designed with key features such as capable for high peak firing pressure, rigid load structure, curvy envelope and ribs to reduce NVH, light weight 2 split top box manufacturing method. Key strategy is used such as less capital investment in purchasing machines, no/less alteration in current machining and assembly line.

The crank-train is the main source for power development and is the bone structure, which needs to be robust against durability along with fulfilling the functional requirement. With the high specific power requirement and very high In-cylinder pressure, the light-weight crank-train development becomes a challenge. Various simulation tools are now available in the market, which predict the vibration and durability aspects of the crank-train in the very initial stage of development. However, in order to use these tools effectively and with high confidence level, the simulation model first needs to be established with the existing engines through correlation with other FE-solver and various validation processes. The more is the correlation and validation available, the faster and more accurate becomes the future engine development process. This further gives high confidence level to deal with complex systems, when engine vibration and durability aspects are considered.