FAW J6P Intercooler: Deconstructing 14 Critical Parts for Flawless Boost Pressure

This is a complete technical deconstruction of the FAW J6P Intercooler assembly (Chapter 39). This is the “Charge Air Cooler” for the FAW Jiefang CA3250P66K2L1T1E 6×4 dump truck. This is not a “radiator” (which cools water); this is a “Boost Logic” device. Its sole purpose is to cool the hot, compressed air from the turbocharger *before* it enters the engine, which is critical for power, efficiency, and emissions.

The “Turbocharger” (Chapter 16) compresses air to create “boost,” but this compression makes the air extremely hot (150°C+). Hot air is “less dense,” meaning it has less oxygen. The FAW J6P Intercooler is the “Efficiency Logic” device that solves this. It functions as an “air-to-air” heat exchanger. It cools this hot air, making it “cold and dense.”

This “Dense Air Logic” is the key. Cold, dense air contains *more oxygen*. More oxygen allows the engine to burn fuel more completely, which (A) creates *more power* and (B) *lowers combustion temperatures*, which is the primary “Emissions Control Logic” for reducing NOx. A failure in the FAW J6P Intercooler system (like a “boost leak”) is a catastrophic loss of power and efficiency.

This technical guide is an essential resource for chassis technicians and fleet managers. We will analyze all 14 components. We will deconstruct the “Core Exchange Logic” (the intercooler itself), the “Hot Side Plumbing Logic” (from the turbo), the “Cold Side Plumbing Logic” (to the engine), and the “Sealing & Protection Logic” (the critical clamps, gaskets, and guard net).

Core 1: The “Charge Air Cooling” Logic (Component 1)

This component is the “heart” of the entire FAW J6P Intercooler system. It is the “workhorse” where all heat exchange takes place.

1. Component: ‘Intercooler assy’ (1119010-70U)
This (Comp 1) is the “Heat Exchange Logic.” It is a large “air-to-air” heat exchanger, which means “air” (from the turbo) flows *inside* it, and “air” (from the outside) flows *across* it. It is mounted at the front of the truck, in front of the ‘Radiator assy’ (Chapter 37), to receive the “coldest” “ram air.”

Its “Hot Side Logic” is that hot (150°C+), high-pressure air from the turbocharger (see Core 2) is forced into an “inlet tank” on one side. This hot air then travels through dozens of “tubes” or “cores” that run the width of the assembly.

Its “Cooling Logic” is that “ambient air” (cold, outside air) is forced *across* the *outside* of these tubes as the truck moves. This “Ambient Air Logic,” enhanced by the engine fan (Chapter 20), “wicks” the heat *out* of the charge air and “dumps” it into the atmosphere.

Its “Cold Side Logic” is that the now “cold, dense” (e.g., 50°C) charge air is collected in the “outlet tank” on the other side. This air, now rich in oxygen, is ready to be sent to the engine (see Core 3). The main “Failure Logic” for a FAW J6P Intercooler is a “crack” or “puncture” from vibration or road debris, which causes a “boost leak” (a hissing sound, a loss of power, and black smoke).

Core 2: The “Hot Side” Plumbing Logic (From Turbo)

This group is the “Inlet Path.” Its “logic” is to transport the *hot, high-pressure* (30+ PSI) air from the turbocharger to the FAW J6P Intercooler with zero leaks.

1. Component: ‘Turbocharger outlet hose’ (1119057A263)
This (Comp 7) is the “Source Logic.” It connects directly to the “compressor outlet” of the turbocharger. It is a highly-engineered, multi-layer reinforced silicone hose. It *must* be “silicone” to withstand the “dual attack” of (A) extreme 150°C+ heat and (B) “oil mist” from the turbo’s bearings. A standard rubber hose would “melt” or “dissolve.”

2. Component: ‘Inlet corrugated connecting hose assy’ (1119050-50A)
This (Comp 3) is the “Vibration Isolation Logic.” The “engine” (with the turbo, Comp 7) “twists” on its mounts, but the “chassis” (with the **FAW J6P Intercooler**, Comp 1) does not. This “corrugated” (bellows-style) hose is a “flexible joint” that “couples” the engine to the chassis plumbing. Its “flexibility” is what prevents the engine’s vibration from “fatigue cracking” the rigid pipes.

3. Component: ‘Intercooler inlet pipe’ (1119031-14B)
This (Comp 4) is the “Rigid Ducting Logic.” It is the pre-formed steel or aluminum pipe that “bridges the gap” between the flexible “corrugated” hose (Comp 3) and the ‘Intercooler assy’ (Comp 1) inlet. It is rigid to prevent it from “ballooning” under boost.

Core 3: The “Cold Side” Plumbing Logic (To Engine)

This group has the “opposite” logic: to transport the now *cold, dense* air *from* the FAW J6P Intercooler *to* the engine’s intake manifold with zero leaks.

1. Component: ‘Outlet corrugated connecting hose assy’ (1119060-50A)
This (Comp 12) is the “Cold Side Vibration Logic.” It is the flexible “coupler” that connects the *outlet* of the ‘Intercooler assy’ (Comp 1) to the ‘Engine inlet pipe’ (Comp 9). Like Comp 3, it is “corrugated” to “absorb” the “differential movement” between the chassis-mounted intercooler and the vibrating engine.

2. Component: ‘Engine inlet pipe’ (1119062-14B)
This (Comp 9) is the “Final Delivery Logic.” It is the rigid, pre-formed pipe that “delivers” the cold, dense, oxygen-rich air to the final component: the engine’s intake manifold.

3. Component: ‘Inlet pipe gasket’ (1119064-50A)
This (Comp 8) is the “Final Seal Logic.” This is a “Smallest Serviceable Unit” (SSU) of *extreme* importance. It “seals” the ‘Engine inlet pipe’ (Comp 9) to the engine’s intake manifold.

A failure (a “gasket blowout”) here is a “boost leak” that causes a “hissing” sound, a loss of power, and black smoke. Even worse, if the leak is on the “suction” side of the turbo (if applicable, though unlikely here), it will “suck in” *unfiltered, dirty* air. This “Dirty Air Logic” will “dust” the engine, “sandblasting” the pistons and cylinders and leading to a “total engine rebuild.”

Core 4: The “Sealing & Protection” Logic (The SSU)

This final group contains the SSUs that “hold” the FAW J6P Intercooler system together and “protect” it from physical damage.

1. The “Sealing Logic” (Components 2, 6)
This includes the ‘Heavy duty hose clamp’ (T67610006A) – Qty 4 and ‘Heavy duty hose clamp’ (T6767606A) – Qty 2. These six clamps are the “Boost-Proof Logic.” A simple “worm-gear” clamp (from a hardware store) would “slip” or “strip” under boost.

These are “T-Bolt” or “Heavy Duty” clamps. Their “logic” is to provide a 360-degree, “high-torque” “clamping force” on the reinforced hoses (Comp 3, 7, 12). This is what prevents the hoses from “blowing off” the rigid pipes under 30+ PSI of boost pressure.

2. The “Protection Logic” (Component 14)
‘Guard net assy’ (1310010A50AJ). This (Comp 14) is the “Physical Armor Logic.” The ‘Intercooler assy’ (Comp 1) is made of… “soft” aluminum, with paper-thin “fins.” A single “rock” or large “bug” thrown up from the road at high speed will “puncture” the core or “flatten” the fins (blocking airflow).

This ‘Guard net’ is a “sacrificial” screen. It is “bolted” (Comp 13) in front of the FAW J6P Intercooler. Its “logic” is to “absorb the impact” of road debris, “sacrificing” itself to “protect” the expensive, delicate intercooler core behind it.

3. The “Fastener” Logic (Components 5, 10, 11, 13)
This is the “Hardware Logic.” It includes all the ‘Hexagon flange bolts’ (Comp 5, 10), ‘Connecting bolts’ (Comp 11), and ‘Combination bolts’ (Comp 13). These are “flanged” (self-locking) bolts. This “Vibration-Proof Logic” is essential to “secure” the ‘Guard net’ (Comp 14) and the ‘Inlet/Outlet pipes’ (Comp 4, 9) to their mounting points, ensuring they never “rattle” loose.

FAW J6P Intercooler & Plumbing Parts List

The following table provides the complete, detailed breakdown of all 14 component types in the FAW J6P Intercooler assembly (Chapter 39) for the FAW Jiefang CA3250P66K2L1T1E 6×4 dump truck.

Core Specifications

The specifications for the FAW J6P Intercooler system are defined by its function as the primary charge air cooling unit for maximizing engine power and efficiency.