HOW TO USE THIS MANUAL

For easy reference and quick identification, Engine is divided into several groups which is classified according to the
basic engine elements which is analogous with parts catalogue.
Each service operation is separated in 3 sections which are: Disassembly, Inspection and Reassembly.
Cleaning of removed parts is not written in the manual, but it must be ensured performing actual service operation.

TERMS AND UNITS

The terms & units used in this manual are:-
1 Front and Rear
The term "Front" is the fan side and " Rear" the flywheel side of the engine.
2 Right and Left
The terms "Right" and "Left" is used to indicate the side as viewed from the flywheel side of the engine.
3 Model Abbreviation
Ÿ E83 NA - Applicable for only E483 Naturally Aspirated.
Ÿ E483 TC- Applicable for only E483 Turbo charged Engine.
Ÿ E483 TCI- Applicable for E483[TCI] with Mechanical Pump
Ÿ E483TCI EDC- Applicable for E483TCI Electronic Diesel Control [EDC] only.
Ÿ E483TCI CRS-BSIV Applicable for E483TCI with Common Rail System.
Ÿ E483 NC BSII / BSIII / BSIV- Applicable for E483 CNG BSII / BSIII / BSIV Models.
Ÿ Power Rating- Power ratings are mentioned if the topic is specific for some particular rating.

4) Service Standard terms.

• Nominal Value
Shows the specified dimensions, dimension of an individual part, standard clearance between parts in an
assembly, or the standard performance of an assembly. Nominal value is denoted by "NV".
• Limit
Shows the value of a part at which the part is no longer serviceable from the performance as well as strength
viewpoints, requiring replacement or repair. Limit is denoted by "L".
5) Tightening Torque
Over or under tightening of bolts and nuts has critical effects on performance and functions.
Tightening torque is therefore specified for some tightening points.
All tightening torque specifications may be considered as "dry" unless "wet" is specified.
Where no tightening torque is specified, use a torque value specified in the General Bolts and Nuts Tightening
Torque Table.
6) Units
For length, weight, areas, and volume, the SI unit (International System of Units) is used with the metric
notation jointly shown in parentheses.
Temperature is shown in centrigrade (°C).
*All dimensions are in mm unless specified otherwise.
 COMPILATION OF THIS MANUAL - READING THE ILLUSTRATION

1. READING THE ILLUSTRATION

(Ex. 1 : Disassembly and Inspection)

4
* Projection from
crankcase top surface 5 Breakage, damage
NV : 0.01 to 0.50
6

Damage,
Indicates the discoloration
service standards. 3 Carbon deposits, scratches
8
on outer surfaces, cracks,
7 discoloration.

9 Cracks, oil hole clogging

* Connecting rod end play

NV : 0.15 to 0.45
L : 0.6
Damage Indicates visual checks.

* indicates inspection to
be made before disassembly.
2
Damage on outer and inner
surfaces, corrosion, flaking

Damage on outer and inner

2
surfaces, corrosion, flaking

Number assigned indicate a typical disassembly sequence.

1. Connecting rod cap 5. 2nd compression ring

2. Connecting rod bearing 6. Oil ring
3. Piston 7. Snap ring
4. 1st compression ring 8. Piston pin
9. Connecting rod
Indicates that the disassembly
procedure is explained in the text.
 COMPILATION OF THIS MANUAL - READING THE ILLUSTRATION

(Ex. 2 : Reassembly)

Gives instruction for jobs to

be done at reassembly

Apply engine oil Piston projection

NV : 0.43 to 0.69
3
Indicates a typical
assembly sequence
4
5
6
< Assembly sequence>
7
17 11 16
8 14 15 12
10 11 13 1
3 9 8 7 6 5 4 2
9

17
Indicates that the
assembly procedure
is explained in the text

100 N m
(10.5 kgf m) 11
14 15 16 13 2 1 10 Face oil groove to crankshaft
(wet)
End play
NV 0.10 to 0.25
L 0.4

Indicates the service

Specifies the tightening torque standards
(wet) means the part must be tightened in wet state
(i.e. engine oil application on threads).
COMPILATION OF THIS MANUAL - GENERAL PRECAUTIONS FOR SERVICING

2. GENERAL PRECAUTIONS n For alignment and punching marks, select a

FOR SERVICING position that would not mar the appearance
and function of the part.
Before starting the service procedures, check
the vehicle for total distance driven, vehicle n Clearly distinguish parts to be replaced from
usage condition, user's complaints and those to be reused.
requests to know exactly the engine condition.
Record information where necessary.
To ensure you are doing correct and efficient
service jobs, observe the following
precautions:

7) Oil seals, packing, O-rings and other rub-

1) Before performing the service procedures ber parts, gaskets and split pins must be
given in this manual, know the trouble spots replaced with new ones whenever they are
and isolate possible causes to determine removed. For replacement, use Genuine
whether removal or disassembly is required. EICHER parts.
2) Select a flat surface for the service job.
3) When servicing the electrical system, be
sure to disconnect the (negative) cable from
the battery.
4) Carefully check parts for oil leaks before
cleaning. After cleaning, it may be difficult to
spot defective areas.
5) Keep ready and make effective use of the
special tools required for servicing. Use the
right tools (specified special tools) in the 8) Apply the specified grease to U-packings,
right place to prevent damages to parts and oil seals, dust seals and bearings before
personal injury. installation.
6) Make alignment marks and keep disassem- 9) When work requires more than one person
bled parts neatly arranged to ensure that always ensure mutual safety. Never play
they are reassembled into the right with switches and levers.
positions. 10) Make sure that your shoes are free from
grease and oil especially when working on
n Special care must be taken for assemblies
heavy items.
involving number of parts, similar parts, or
parts identical at right ad left-hand sides to
ensure correct reassembly.
11) When checking or changing lubricants, wipe off 13) Care to be taken so that hands and fingers are
grease, oil and dirt from parts immediately with not injured by sharp edges or corners of parts.
waste cloth. 14) Wear safety goggles whenever handling a
12) Special care must be taken in handling sensors grinder or welding machine. Wear gloves to
and relays which are susceptible to shock and ensure utmost safety.
heat.
 00

GENERAL

CONTENTS

1. ENGINE NUMBER CODIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 02

2. GENERAL BOLTS AND NUTS TIGHTENING TORQUE TABLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 03
3. REMOVAL AND INSTALLATION OF ENGINE FROM VEHICLE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04
3.1. SERVICE STANDARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 04
3.2 SERVICE PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05
3.2.1 PREPARATION BEFORE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 05
3.2.2 REMOVAL OF ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 06
3.2.2.1 Removal of Coolant and Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 06
3.2.2.2 Removal and Installation of Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 07
3.2.2.3 Removal and Installation of Hoses, Pipes,
Cables and Cooling Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 09
3.2.2.4 Removal and Installation of the parts from/to the Transmission . . . . . . . . . 11
3.2.2.5 Removal and Installation of the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2.3 OPERATIONS AFTER INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4. ENGINE REMOVAL FROM VEHICLE FLOW CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
5. COMPLETE ENGINE DISASSEMBLY SEQUENCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

00-1
00 GENERAL - ENGINE NUMBERS

1. ENGINE CODIFICATION INFORMATION (OLD)

Engine number
stamped here

The engine number is stamped on the rear of the

crankcase as illustrated.

E 4 83 N C 4 A 100000
Running serial number
Month of production (A to M except I)
Year of production (Last digit only)
Type of fuel ( D=Diesel, C=CNG,L = LPG)
Version (N=Naturally aspirated, C=TCI, T=TC)

Swept volume per cylinder

No. of Cylinder (4 or 6)
EICHER

00-2
 GENERAL - ENGINE NUMBERS 00
2. ENGINE CODIFICATION INFORMATION (NEW)

Engine number
stamped here

Engine Codicaation Nomencture

EDS = Engine Descripti
ve Section
EIS = Engine Indicator Section
EDS EIS
E 4 1 3 C D E H XXXXXX

Running Serial Number

Month of Manufacturing (A to M except I)

Year of Manufacturing

Type of fuel [D=Diesel, C=CNG, L = LPG]

Version [N=NA, C=TCI, T=TC]

Emission Norms [Refer Table 5]

1-2 Valve, 0.83 Ltrs.
2-4 Valve, 0.94 Ltrs.
No. of Cylinder (4 or 6)
EICHER
Table - 5
CODES
Sr. No. Engine Type
1 2 3 4
1 Auto BSI BSII BSIII BSIV

00-3
00 ENGINE- GENERAL BOLTS AND NUTS TIGHTENING TORQUE TABLE

2. GENERAL BOLT AND NUT TIGHTENING TORQUE TABLE

Unless otherwise specified, the parts and equipment of the vehicle must be tightened by the
following bolts and nuts, tightening torque standards.

NOTE :
Threads and seat surfaces must be in dry state.
Standard bolts and nuts. Unit : Nm(kgf m)

Dia. mm. Pitch mm. 4T (Head mark 4) 7T (Head mark 7) 8T (Head mark 8)
5 0.8 2.0 to 2.9 (0.2 to 0.3) 3.9 to 5.9 (0.4 to 0.6) 4.9 to 6.9 (0.5 to 0.7)
6 1.0 3.9 to 5.9 ( 0.4 to 0.6) 6.9 to 10.8 (0.7 to 1.1) 7.8 to 11.8 (0.8 to 1.2)
8 1.25 8.8 to 13.7 (0.9 to 1.4) 16.7 to 25.5 (1.7 to 2.6) 19.6 to 29.4 (2.0 to 3.0)
1.25 18.6 to 27.5 (1.9 to 2.8) 34.3 to 53.9 (3.5 to 5.5) 44.1 to 58.8 (4.3 to 6.0)
10
1.5 17.7 to 26.5 (1.8 to 2.7) 32.4 to 49.0 (3.3 to 5.0) 42.1 to 58.8 (4.3 to 6.0)
1.25 33.3 to 49.0 (3.4 to 5.0) 68.6 to 93.2 (7.0 to 9.5) 83.4 to 108 (8.5 to 11)
12
1.75 30.4 to 46.1 (3.1 to 4.7) 63.7 to 83.4 (6.5 to 8.5) 73.5 to 98.1 (7.5 to 10)
1.5 58.8 to 83.4 (6.0 to 8.5) 118 to 157 (12 to 16) 127 to 177 (13 to 18)
14
2.0 53.9 to 73.5 (5.5 to 7.5) 108 to 137 (11 to 14) 118 to 167 (12 to 17)
1.5 93.2 to 127 (9.5 to 13) 177 to 235 (18 to 24) 196 to 265 (20 to 27)
16
2.0 88.3 to 118 (9.0 to 12) 157 to 216 (16 to 22) 186 to 255 (19 to 26)
18 1.50 137 to 186 (14 to 19) 255 to 343 (26 to 35) 294 to 392 (32 to 40)
20 1.50 186 ot 255 (19 to 26) 353 to 471 (36 to 48) 402 to 549 (41 to 56)
22 2.50 226 to 304 (23 to 31) 422 to 569 (43 to 58) 490 to 667 (64 to 86)
24 1.50 333 to 451 (34 to 46) 618 to 843 (63 to 86) 726 to 981 (74 to 100)

Flange bolts and nuts. Unit : Nm(kgf m)

Dia. mm. Pitch mm. 4T (Head mark 4) 7T (Head mark 7) 8T (Head mark 8)
6 1.0 3.9 to 5.9 (0.4 to 0.6) 7.8 to 11.8 (0.8 to 1.2) 8.8 to 13.7 (0.9 to 1.4)
8 1.25 9.8 to 14.7 (1.0 to 1.5) 18.6 to 27.5 (1.9 to 2.8) 21.6 to 32.4 (2.2 to 3.3)
10 1.25 20.6 to 30.4 (2.1 to 3.1) 38.2 to 58.8 (3.9 to 6.0) 49.0 to 63.7 (5.0 to 6.5)
12 1.25 37.3 to 53.9 (3.8 to 5.5) 78.5 to 108 (8.0 to 11) 88.3 to 118 (9.0 to 12)

00-4
 REMOVAL & INSTALLATION OF ENGINE - SERVICE STANDARDS 00
3. REMOVAL AND INSTALLATION OF ENGINE FROM VEHICLE
3.1. SERVICE STANDARDS
Tightening Torque Table

Part to be tightened Thread size dia. Tightening torque

x pitch mm. N m (kgf m)

Flange yoke to propeller shaft mounting companion flange tightening nut M12 x 1.25 98 to 115 (10 to 12)

Clutch power cylinder mounting bolt. M10 x 1.25 38 to 59 (3.9 to 6)

Cross shaft mounting bolt M8 x 1.25 15 to 20 (1.5 to 2)

Front M10 x 1.25 59 to 78 (6 to 8)

mounting Front engine support mounting bolt

M12 x 1.25 98 to 115 (10 to12)

Front engine cushion rubber mounting nut (upper) M12 x 1.25 78 to 98 (8 to 10)

Front engine cushion rubber mounting nut (lower) M12 x 1.25 34 to 44 (3.5 to 4.5)

Front mounting bracket mounting bolt M10 x 1.25 59 to 78 (6 to 8)

Rear Upper type Rear engine support lower mounting bolt/nut M10 x 1.25 59 to 78 (6 to 8)

mounting Rear engine support upper mounting bolt/nut M14 x 1.5 125 to 155 (13 to 16)

Rear mounting cushion rubber mounting nut M8 x 1.25 20 to 26 (2 to 2.7)

Bus Shock absorber lower part mounting nut

Refer to Group 26 Front Axle
Drag link end plug

00-5
00 REMOVAL AND INSTALLATION OF ENGINE - SERVICE PROCEDURE

3.2. SERVICE PROCEDURE

3.2.1 Preparation Before Removal

The illustration below shows the direction of removal of the engine and transmission

< Tilt cab models > < Bus models >

1200 or more

For tilt cab models, remove the engine and Raise the vehicle to obtain a clearance of
transmission as an assembly, raising it 1200 mm and place rigid racks to the front
upward off the frame. and rear of the frame.

NOTE :
Allow the engine to cool down sufficiently
before its removal.

Disconnect negative cable from the battery

Place chocks to rear wheels.

00-6
 REMOVAL AND INSTALLATION OF ENGINE - SERVICE PROCEDURE 00
3.2.2 Removal Of Engine
3.2.2.1 Drainage of Coolant and Brake Fluid

Drainage of coolant

3 Crankcase drain plug

2 Radiator drain plug

Brake

Clutch

1
Apply chocks

4 Drain brake fluid

NOTE :
Take care not to spill the brake
fluid as it attacks the paint.

00-7
00 REMOVAL AND INSTALLATION OF ENGINE - SERVICE PROCEDURE

3.2.2.2 Removal and Installation of Harness

< L.H. of vehicle >

1 Engine Starter Motor Connection

2 Backup lamp switch

3 Engine ground
cable

< R.H. of vehicle >

6 Oil bypass
alarm
1 Water temperature
gauge unit
2 Alternator L, R terminal

3 Alternator B terminal

5 Oil pressure switch 4 Exhaust brake 3-way

magnetic valve

00-8
 REMOVAL AND INSTALLATION OF ENGINE - SERVICE PROCEDURE 00
Removal and Installation of Harness

(CNG) 1 Ignition Coil

2 Cable Spark Plug
3 Lamda Sensor
+ve From Battery

-ve From Ignitor

10
Speed 9 8
Sensor Ignition Sub Harness
Line CNG 4 Wiring Harness IMPCO
12 Timing Sensor CNG
Fuel Level
11
13 Electronic Control Indicator IMPCO
A VI - 151 15-2

Unit (Ignitor) IMPCO

A VI - 151 15-2

5 Fuel Control Valve

6 Wiring Harness Gill

14 IMPCO ECU 7 System Protection Circuit

Cable Battery Cable Battery Cut off Switch A
Cut off Switch B

15 Communication Port

A : BATTERY

(E483 EDC)
1 Water Temp Sensor

2 Needle Movement Sensor

(Engine Position Sensor)
3 Boost Pressure Sensor

4 Electrical Actuators

5 Engine speed sensor

7 Vehicle Speed Sensor

6 Vehicle Speed Sensor

00-9
00 REMOVAL AND INSTALLATION OF ENGINE - SERVICE PROCEDURE
3.2.2.3 Removal and installation of Hoses, Pipes and Cooling Components

Removal of radiator
Upper hose Cooling fan Radiator support bracket

Lower hose

Lower
Water temperature bracket
gauge unit
Oil pressure
switch
Harness starter motor

Control cables
E483

Exhaust brake unit

Fuel hoses Brake hose

NOTE :
After removal of the hose, hold its end at higher level than the fuel tank to prevent the fuel
from flowing out of the hose.

00-10
 REMOVAL AND INSTALLATION OF ENGINE - SERVICE PROCEDURE 00
Removal and installation of Hoses, Pipes and Cooling Components

(CNG)
1 High pressure
Regulator valve

2 Hose HPRV
3 Hose Low pressure
14 Bracket mtg. Clamp. 4 Vacuum Lock of Filter
5 Low Pressure Regulator

13 Hose Water CNG

12 Hose Water 6 Bracket - LPRV
7 Hose Vapor CNG
11 Hose Compressor 8 Hose Vacuum
Outlet
9 Hose Compressor inlet

10 Hose Air Cleaner

(E483 EDC)

1 Water Temp Sensor

2 Needle Movement Sensor

(engine Position Sensor)
3 Boost Pressure Sensor

4 Electrical Actuators

5 Electrical Actuators

Note :- Reassembly sequence is reverse of disassembly.

00-11
00 REMOVAL AND INSTALLATION OF ENGINE - SERVICE PROCEDURE

3.2.2.4 Removal and Installation of the Parts from/to the Transmission (LD)

(Cable Type)

Select rod Shift rod

Select Cable

Shift
Cable
Cross shaft
Cross shaft

15 to 20 Nm
(BS-IV)
(1.5 to 2 kgfm)
For removal and installation
of the mounting, refer to
Select rod
Section 2.2.4 1(b).
Shift rod

Parking brake cable

<Center bearing side>

Speedometer cable < Parking brake side > Propeller shaft

Clutch release
rocker arm
47 to 65 Nm
(4.8 to 6.6 kgfm)

98 to 115 Nm
(10 to 12 kgfm)
Brake lever Mating marks

Power cylinder NOTE:

Make the mating marks before removal.
Remove from the center bearing side.
Rear plate

38 to 59 Nm
(3.9 to 6 kgfm) Parking brake cable
NOTE:
1. Remove Propeller Shaft.
2. Tie Propeller Shaft to the frame using a rope.
3. Remove Power Master Cylinder
4. Do not disconnect Clutch hose.
5. Tie Power Master Cylinder to the frame.
(Note: Also Refer Group 21 Clutch and Group 22 Transmission for further details.)

Note :- Reassembly sequence is reverse of disassembly.

00-12
 REMOVAL AND INSTALLATION OF ENGINE - SERVICE PROCEDURE 00
Removal and Installation of the Parts from/to the Transmission (MD)

Select rod

Shift rod

(BS-III)
Select rod
Engine speed sensor
Shift rod

Vehicle speed sensor

Speedometer cable
Propeller shaft

Clutch release
rocker arm

38 to 59 Nm
(3.9 to 6 kgfm) Mating marks
47 to 65 Nm
Rear plate 98 to 115 Nm (4.8 to 6.6 kgfm)
(10 to 12 kgfm)
Power cylinder
NOTE:
Make the mating marks before removal.
Remove from the center bearing side.

NOTE:
1. After removal of the propeller shaft, tie it to the frame using a rope, etc.
2. When removing the power cylinder, disconnection of the clutch hose causes oil flow out, requiring air bleeding later.
3. After removal of the power cylinder, tie it to the frame using a rope, etc.
4. Refer also to Group 21 Clutch and Group 22 Transmission.

00-13
00 REMOVAL AND INSTALLATION OF ENGINE - SERVICE PROCEDURE

3.2.2.5 Removal and Installation of the Engine

1) Vehicles with Tilt Cab

Remove the rear mounting post.

NOTE : Transmission jack

1. Check that all wiring, pipings, and other parts

(a) Hook the engine lifting jig to the hanger of the
have been removed from the engine so that
intake manifold and hook the chain block to the
the engine can readily be removed.
rear plate hole and slowly lift up the engine by a
2. When removing the engine, care to be taken to crane until they become tight.
avoid hitting of the engine against cab and
NOTE :
body.
Adjust the chain block to the same length as the
3. Use a lifting gear or engine lifter that is
engine lifting jig.
capable of lifting the engine weighing 260 to
340 Kg.
For the removal of the transmission, refer to
Section 5.1 Group 22 Transmission.

00-14
 REMOVAL AND INSTALLATION OF ENGINE - SERVICE PROCEDURE 00
(b) Removal and Installation of mounting

<Upper type>
59 to 78 Nm
(6 to 8 kgf m)
59 to 78 Nm
(6 to 8 kgf m)
(Fit the positioning tabs on top and
bottom of the cushion rubber into the
holes in the rear engine support
before tightening.) Cushion rubber
20 to 26 N m n Lost tension

n Flaking
(2 to 2.7 kgfm)
Rear engine support,
lower
(Do not apply engine
* 125 to 155 N m load to bolt when
(13 to 16 kgf m) tightening it.)

Rear engine support, upper

Rear
(Fit the positioning tabs on top and
Front
bottom of the cushion rubber into the
holes in the front engine support
before tightening.)

78 to 98 N m Mounting
(8 to 10 kgf m) bracket
59 to 78 N m
(6 to 8 kgf m)

Cushion rubber
n Lost tension

n Flaking

Front engine
support

*34 to 44 N m
98 to 115 N m (3.5 to 4.5 kgf m)
(10 to 12 kgf m)
<M12 x 1.25> (Fit the head of the
positioning screw of
59 to 78 N m the cushion rubber
(6 to 8 kgf m) into the hole in the
<M10 x 1.25> engine support
before tightening.)
NOTE :
1. When disconnecting the engine from the vehicle, remove the bolt/nut marked with * only
2. Reassembly sequence is reverse of disassembly..

00-15
00 REMOVAL AND INSTALLATION OF ENGINE - SERVICE PROCEDURE

(c) Separate the engine and transmission assembly 2) Vehicles with Bus Body
from the engine and transmission mountings as NOTE :
described below.
1. Check that the engine can be readily removed
with all wiring and pipings removed.
Engine
support
2. When removing the engine, use care not to
Back plate
allow it to hit against the body.
(a) Supporting the engine

(d) Lower the transmission with care not to allow the

transmission back plate to hit against the engine
support and move the engine forward.

Engine lift

Transmission jack

Support the engine and transmission assembly with

the engine lift and transmission jack.

(e) Lift the engine with care not to allow it to hit

against the parts around.
Fine-adjust the engine lifting angle. At the same
time, as the transmission is visible from the rear
body front end, turn the engine 90° clockwise and
place it down on the right side with care not to
allow it to hit against the frame and cab.

00-16
 REMOVAL AND INSTALLATION OF ENGINE - SERVICE PROCEDURE 00
(b) Remove connections on the vehicle side. (d) Removal from the frame

Brake hose

Front suspension

Using care not to allow the engine to interfere with the

side frame, floor, wires, and cables, move the engine
slowly toward the rear and then down. Repeat this step
until the engine top level becomes lower than the
Shock absorber
frame bottom level.
(e) Removal from the body skirt

Drag link

(c) Front engine support and reinforcement

Skirt

Reinforcement

Using care not to allow the engine top to interfere with

the side frame bottom, turn the engine 90° and
Front engine
support withdraw it under the skirt immediately after the front
wheels
NOTE :
Remove the shock absorbers. 1. Cover the brake hoses and pipes removed
Remove the brake hoses. with a cloth to protect them from dust and dirt.
Separate the knuckle arm from the drag link. 2. Remove the brake hose from the frame end
Separate the front spring from the frame, along with first and install it to the brake end first. Ensure
the Front Axle Assembly. it is not twisted.

Remove the propeller shaft. 3. See the following groups for the removal and
installation procedures :
26 Front Axle
33 Front Suspension

00-17
00 REMOVAL AND INSTALLATION OF ENGINE - SERVICE PROCEDURE

3.2.3 Operations After Installation (c) Bleed the fuel system (Refer to Group 13 of
Engine Shop Manual).

Max

Min

(a) Tighten the oil pan drain plug to specified torque

and fill the engine oil to specified level. (d) Pour brake oil, and bleed the system.
Then, check the oil level gauge, allow some time (e) Adjust the accelerator control cable and engine
so that engine oil completely reaches the oil pan. stop cable. (Refer to Group 13 Engine Shop
Manual).
NOTE :
Before checking the level with the level gauge,
allow some time so that engine oil completely
reaches the oil pan.

d
Goo

(f) Connect the battery grounding.

(b) Tighten the crankcase drain plug to specified

torque and tighten the radiator drain plug firmly
and pour engine coolant to specified level. After
pouring, check that the coolant is filled to the brim
of the radiator cap and to the FULL level in the
reservoir tank. If the level is lower, replenish.
l Use soft water mixed with 50% Antifreeze
Solution (Make : GOLDEN CRUISER)

(g) Start the engine and let it run at idle for a while to
make sure that all parts operate properly. Check
closely for oil leak, coolant leak and unusual
noise.

00-18
 GENERAL - SERVICE PROCEDURES 00
4. ENGINE REMOVAL FROM VEHICLE FLOW CHART
E483 NA, E483TC and E483 TCI
Remove battery connections [-ve]
connection from battery

Remove Starter motor Connections.

Drain Engine Oil

Drain coolant from radiator and

crankcase.

Drain power steering oil

Remove radiator assembly and

cooling fan.

Remove fuel line connections

from feed pump & injector return line

Remove Intake manifold and

turbocharger hoses

Remove accelerator cable from FIP

Remove Clutch and transmission

assembly [Please refer chassis shop
manual, group 22, sec 5.1]

Remove engine front and rear

mounting cushion and its brackets.

Remove engine from vehicle and

mount on engine overhauling stand

00-19
00 GENERAL - SERVICE PROCEDURES

E483 NC BSIII

Close OMB Valve

Remove Mixer Assembly

Close 3 way Valve

Remove Ignition Coil & HT Cable

Remove battery connections [-ve]

connection from battery
Remove Intake manifold and
turbocharger hoses

Remove Starter motor Connections.

Remove Clutch and transmission
assembly [Please refer chassis shop
manual, group 22, sec 5.1]

Drain Engine Oil

Remove engine front and rear
mounting cushion and its brackets.

Drain coolant from radiator and

crankcase.
Remove engine from vehicle and
mount on engine overhauling stand

Drain power steering oil

Remove Accelerator Cable

Remove radiator assembly and

cooling fan.

Remove (fuel line) Regulator to

Mixer

Remove HPRV Coolant connection

Remove Sensor Harness

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 GENERAL - SERVICE PROCEDURES 00
E483 NC BSIV

Close OMB Valve Remove Rail and Injector

Close 3 way Valve Remove Electronic throttle body

Remove battery connections [-ve] Remove Ignition Coil & HT Cable

connection from battery

Remove Intake manifold and

Remove Starter motor Connections.
turbocharger hoses

Remove Clutch and transmission

Drain Engine Oil assembly [Please refer chassis shop
manual, group 22, sec 5.1]

Drain coolant from radiator and Remove engine front and rear
crankcase. mounting cushion and its brackets.

Remove engine from vehicle and

Drain power steering oil
mount on engine overhauling stand

Remove radiator assembly and

cooling fan.

Remove (fuel line) HPRV to rail

Remove HPRV Coolant connection

Remove Sensor Harness

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00 GENERAL - SERVICE PROCEDURES

5. COMPLETE ENGINE DISASSEMBLY SEQUENCE

The flow chart shows the overview of disassembly sequence of major components of engine, for complete details
please refer the respective section reference number.

Starter Motor
Rocker Assembly
Reference No. ( 16.05.02 )
Reference No. (11.05.2.1)

Drive Belt Head Assy.

Reference No. (11.05.2)

Reference No. (00.03 )

Fan Pulley Oil Filter Assy.

Reference No. (12.05.03)

Reference No. (00.03 )

Oil Pan
Alternator
Reference No. (12.05.02 )
Reference No. (16.05.02 )

Water pump
Compressor
Reference No. (14.05.02)
Reference No. ( 16.A )
Power Steering Pump
Turbo Charger Reference No. (00.03 )

Reference No. (15.04.06)

Damper pulley
Reference No. (14.05.01)
Exhaust & inlet Manifold

Reference No. (15.04.03) Timing Case & Gears

Reference No. (11.05.4.1)

Feed Pump

Reference No. (13.05.06) Camshaft

Reference No. (11.05.1.5)

Fuel Filter

Connecting Rod Piston

Reference No. (13.05.08)
Reference No. (11.05.5.1) Reference No. (11.05.15)
Flywheel Assembly
Crank Shaft
Reference No. (11.05.3.1)
Reference No. (11.05.5.1)
Fuel Injection Pump

Reference No. (13.05.01)

*This is normal complete disassembly sequence ,it may vary as per service requirement.

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