✅ Auto Rickshaw Full Engine Fitting – Step by Step Guide (Simple English)

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✅ Auto Rickshaw Full Engine Fitting – Step by Step Guide (Simple English)

            Indruction 

Hello friends, welcome to Rajesh Technical Blog.
Today I will tell you step by step how to do auto rickshaw full engine fitting.

Auto rickshaw engines are small, efficient and easy to repair if you follow the correct step-by-step process. In this guide, you will learn the complete engine fitting method from start to finish. Whether you are a beginner or a technician, this tutorial will help you understand the full procedure clearly.

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⭐ 1. Prepare the Tools and Workspace

Before starting the engine fitting, keep all the required tools ready. A clean workspace makes the job easy and fast.

Tools needed:

• Spanners (8mm to 17mm)
• Socket set
• Screwdrivers
• Torque wrench
• Engine mounting bolts
• Fuel line clamps
• Oil measuring cup
• Clean cloths

Make sure the rickshaw is parked on a flat surface and the battery is disconnected.

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⭐ 2. Install the Engine on the Mounting Bracket

Place the engine carefully on the rear mounting bracket.

Steps:

1. Align the engine with the mounting holes.
2. Insert the mounting bolts from both sides.
3. Tighten the bolts slightly first.
4. After alignment, tighten them fully using a torque wrench.

Correct mounting is important because the engine should not vibrate excessively.

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⭐ 3. Fit the Gearbox and Clutch Assembly

Auto rickshaws mostly use simple gear and clutch systems.

Procedure:

• Align the gearbox shaft with the engine shaft.
• Insert the clutch bell and tighten the nut.
• Check clutch play and adjust if needed.

Make sure there is no unusual noise or tightness in rotation.

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⭐ 4. Connect Fuel Line and Oil Line

Fuel supply must be clean and leak-free.

Do this:

• Connect the fuel line to the carburetor or fuel injector.
• Tighten the clamp.
• Connect the engine oil line (if separate).
• Check for any leakage.

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⭐ 5. Install the Exhaust Pipe

Align the exhaust with the engine port.

Steps:

• Fix the gasket properly.
• Insert bolts and tighten.
• Ensure there is no smoke leakage around the joint.

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⭐ 6. Connect Wiring and Electricals

Modern rickshaws have simple electrical wiring.

Connect these:

• CDI unit
• Ignition coil
• Spark plug wire
• Rectifier (charging system)
• Ground wire

After connecting everything, tie the wires so they don’t touch hot engine parts.

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⭐ 7. Fit the Carburetor or Fuel Injection Unit

If it’s a carburetor model:

• Fit carburetor to the intake manifold
• Tighten clamps
• Connect choke and accelerator cable

If it’s a FI model:

• Fit injector
• Connect sensor wiring

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⭐ 8. Fill Engine Oil and Coolant

Always use company-recommended oil.

Steps:

• Pour engine oil to correct level
• Check with dipstick
• Add coolant if the model supports liquid cooling

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⭐ 9. Final Inspection Before Starting

Check everything carefully:

• All bolts tight
• No fuel leaks
• Wiring connected
• Engine rotates freely by hand
• Air filter installed
• Battery connected

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⭐ 10. Start the Engine for the First Time

Now start the engine.

Observe:2025/11/mahindra-thar-complete-parts-list-with

• Engine idling speed
• Smoke color
• Any unusual sound
• Proper vibration level

Let the engine warm up for 5–7 minutes.
Adjust carburetor settings if needed.

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⭐ Final Words

Friends, if you found this post useful then share it with your friends and if you want to ask something then you can ask me by commenting.

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