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 block and head design made with the help of CAD, CAE, and simulation software to perform required design and analysis results. Test results were correlated.