Forklift Cylinder Liner 490B-01005 – Xinchai 490 4D27

Forklift Cylinder Liner 490B-01005 — Xinchai 490 / 490BPG / A490BPG / C490B / 4D27 Diesel Engine Cylinder Liner

This forklift cylinder liner part number 490B-01005 (cross-reference 80033020159) is a Kingstream OEM cylinder liner for Xinchai 490BPG, A490BPG, C490B, and 4D27 4-cylinder diesel engines in 1-3.5 ton forklift trucks, construction equipment, and agricultural machinery. The cylinder liner is the replaceable cylindrical sleeve pressed into the engine block that forms the cylinder bore — it provides the precision-machined running surface for the piston and piston rings, contains combustion pressure, and transfers combustion heat to the engine coolant through the cylinder block. This is a wet-type cylinder liner with direct coolant contact on the outer surface. Steel alloy construction with silver or customized finish. Dimensions: 109×100×90×182mm. Weight: 2.35kg net (2.6kg gross) with 19×19×24cm packaging. 4 pieces per engine set. 100% brand-new. 6-month warranty. Kingstream OEM quality for Xinchai 490 diesel engine rebuild programs.

INSTALLATION PROCEDURE: Step 1 — Remove the engine from the forklift and disassemble to expose the cylinder block. Remove the cylinder head, oil pan, pistons, and connecting rods. Step 2 — Use a cylinder liner puller tool to extract the old liners from the block. Step 3 — Thoroughly clean the cylinder block liner bores — remove all rust, scale, and old sealant from the liner seat and seal areas. The liner seat at the bottom of the bore must be absolutely clean and smooth for proper liner protrusion. Step 4 — Inspect the block for cracks, especially between cylinder bores and at the deck surface. Step 5 — Measure the new liner outside diameter and the block bore diameter to verify correct interference fit. Step 6 — Install new O-ring seals on the new liner — lubricate the O-rings with clean engine oil or rubber lubricant. NEVER use grease on liner O-rings as it can prevent proper seating. Step 7 — Press each new liner into the block bore by hand or using a liner installation tool. The liner should slide in with firm, even hand pressure — if excessive force is required, stop and verify correct liner and bore dimensions. Step 8 — Measure liner protrusion above the cylinder block deck surface using a depth micrometer and straightedge. Xinchai 490 specification is typically 0.05-0.15mm protrusion. Uneven protrusion causes head gasket failure. Step 9 — After all liners are installed, hone the cylinder bores to achieve the correct crosshatch pattern (typically 45-60 degrees) for proper piston ring seating. Step 10 — Measure each bore for diameter, taper, and out-of-round using a bore gauge. Step 11 — Clean all honing debris thoroughly before reassembly. Reinstall pistons with new rings, cylinder head with new head gasket, and complete engine assembly. 6-month warranty. Kingstream OEM.

SYMPTOMS OF CYLINDER LINER FAILURE: Excessive blue or white exhaust smoke (oil or coolant entering combustion chamber), coolant in engine oil (milky appearance), engine overheating, loss of compression in one or more cylinders, piston scuffing or seizure, coolant loss without external leaks, and bubbles in the radiator indicating combustion gas leakage past the liner O-ring seals. For Xinchai 490 diesel engine fleet overhaul programs, contact us. Kingstream OEM.

Technical Specifications

6-month warranty. 100% brand-new. Kingstream OEM. Contact us.