FAW Intercooler: A Critical Guide to Its 36 Ducting and Mounting Components

Welcome to this critical technical guide on the FAW Intercooler (Parte não. 1119010-90U), the complete charge-air-cooling system for the FAW Jiefang CA4251P66K24T1A3E5 6×4 diesel semi-trailer tractor. This system is absolutely essential for engine power, eficiência, and emissions control.

O FAW Intercooler, also known as a Charge Air Cooler (CAC), has one vital job: to cool the high-temperature air that has been compressed by the turbocharger. Cooling this “charge air” makes it much denser, allowing the engine to burn more fuel, which dramatically increases horsepower and torque.

This in-depth guide is an essential resource for professional technicians, fleet managers, and parts specialists. We will deconstruct the entire FAW Intercooler assembly and its 36 serviceable components, including the cooler core, the debris grille, all associated ducting and piping, and the complex, vibration-isolating bracket system.

Core Component: The Intercooler Assembly (1119010-90U)

The heart of this system is the ‘Intercooler Assembly’ (1119010-90U), which is the main FAW Intercooler core. This is a large, air-to-air heat exchanger that sits at the front of the truck, typically in front of the main engine radiator.

Its operation is simple but critical. Hot, compressed air from the turbocharger (which can be over 150°C / 300° f) is forced through hundreds of internal tubes and fins. As the truck moves, cool, ambient air from the outside is forced through the *external* fins of the FAW Intercooler. Esse “air-to-air” exchange rapidly pulls the heat out of the compressed “charge air” before it is sent to the engine’s intake manifold.

This cooling process is essential. Colder air is denser air. Denser air contains more oxygen molecules per cubic foot. More oxygen allows the engine’s ECU to inject more fuel, resulting in a more powerful combustion stroke. This is the entire principle of “turbo-charging,” and the FAW Intercooler is the component that makes it efficient. A clogged or leaking FAW Intercooler will result in a severe loss of engine power, high black smoke, and poor fuel economy.

The Protective Grille (1310050-90U)

The ‘Grille assembly’ (1310050-90U) is the primary protective component for the FAW Intercooler. The intercooler’s design relies on thousands of very thin, delicate aluminum fins to transfer heat. These fins are extremely soft and can be easily bent or damaged.

This grille, ou “debris net,” is mounted directly in front of the FAW Intercooler. Its sole purpose is to stop large debris—such as rocks, gravel, large insects, birds, and road debris—from impacting the core. A single rock thrown by a truck in front can puncture a tube in the FAW Intercooler, creating a massive “boost leak” and disabling the vehicle.

Even non-puncturing debris, like a swarm of insects or a buildup of leaves, can clog the external fins. This clogging blocks the flow of cool ambient air, effectively insulating the FAW Intercooler and preventing it from doing its job. This grille assembly ensures the FAW Intercooler core remains clean and protected.

O “Hot Side” Piping: Turbo to Intercooler

O “hot side” of the FAW Intercooler system is the plumbing that carries the hot, compressed air from the turbocharger’s outlet to the intercooler’s inlet. This section includes the ‘Engine intake pipe’ (1119062-74A), which is a rigid, pre-bent pipe that mounts to the engine. It is sealed to the turbo or a connecting flange by the ‘Gasket-intake pipe’ (1119064-590).

Because the FAW Intercooler is mounted on the chassis (which is isolated from the engine), there must be a flexible connection to absorb the engine’s vibration and torque-twist. This is the job of the ‘Corrugated connecting hose assembly’ (1119055-74A) and the ‘Connecting hose’ (1119053K1H).

These are not simple rubber hoses. They are high-temperature, multi-ply silicone hoses, often reinforced with aramid fibers (like Kevlar), to withstand the high temperatures and high pressures of the “hot side” charge air. A failure or “blow-out” of one of these hoses is a very common cause of a sudden, total loss of engine power, accompanied by a loud “whooshing” sound. The integrity of this piping is essential to the Example of FAW Intercooler sistema.

O “Cold Side” Piping: Intercooler to Engine

After the air passes through the FAW Intercooler, it is now “cold” (relative to its inlet temperature) and dense. Esse “cold side” plumbing carries this air from the FAW Intercooler outlet to the engine’s intake manifold.

This part of the circuit includes the ‘Intercooler outlet pipe assembly’ (1119031-91C), which is the rigid pipe connected to the cooler’s outlet. This pipe is then connected to the engine’s intake manifold via the ‘Flexible hose assembly-intercooler’ (1119125-1063) and its associated ‘Bushing’ (1119127-91C).

This flexible hose is the final point of vibration isolation. A leak on this “cold side” is known as a “boost leak” and is a critical performance problem. A boost leak here allows the precious, cold, dense air to escape, resulting in a low-power, high-smoke, and low-efficiency condition. Securing this hose with the ‘Powerful hose clamp’ (T67611006A) is a key part of the FAW Intercooler conjunto.

O “Soft Mount” Bracket and Stay System

O FAW Intercooler is a large, heavy component that is mounted in a high-vibration area. This parts list details an extensive “soft mount” system to protect it. The cooler itself is mounted on the ‘Radiator vertical cushion block assembly’ (1302030-61B) and ‘Radiator flat plate’ (1302040-91C), which isolate it from vertical road shocks.

The entire FAW Intercooler and radiator assembly is held in place by a complex set of brackets:

• ‘Intercooler left lower support bracket’ (1119085-91C)
• ‘Intercooler right lower support bracket’ (1119090-91C)
• ‘Intercooler left upper support bracket’ (1119091-76A)
• ‘Intercooler right upper support bracket’ (1119092-76A)
• ‘Intercooler middle support bracket’ (1119097-76A)

To control fore-and-aft movement, the system uses four ‘Tension rod flexible cushion assembly’ (1302050-01) unidades. These are flexible “stay rods” that connect the radiator/intercooler assembly to the chassis, allowing for slight movement while preventing large, damaging shocks. The ‘Cushion’ (1302052-01) provides the flexible interface. This entire mounting cradle is a key part of the FAW Intercooler‘s long-term reliability.

FAW Intercooler Logic Assembly Parts List

The following table provides the complete, detailed breakdown of all 36 components identified in the ‘Intercooler, Grille, Piping, Suporte’ diagram for the FAW CA4251P66K24T1A3E5 tractor. This entire FAW Intercooler system is critical for engine power.

Technical Specifications and Assembly Context

The specifications for the FAW Intercooler system are defined by its function as a chassis-mounted, vibration-isolated, and heat-shielded air filtration system for a heavy-duty turbo-diesel engine. The entire FAW Intercooler logic assembly is critical for performance.