Refroidisseur intermédiaire FAW: Un guide critique de son 36 Composants de conduits et de montage

Bienvenue dans ce guide technique critique sur le Refroidisseur intermédiaire FAW (Partie no. 1119010-90U), the complete charge-air-cooling system for the FAW Jiefang CA4251P66K24T1A3E5 6×4 tracteur semi-remorque diesel. This system is absolutely essential for engine power, efficacité, and emissions control.

Le Refroidisseur intermédiaire FAW, 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.

Ce guide détaillé est une ressource essentielle pour les techniciens professionnels, gestionnaires de flotte, et spécialistes des pièces détachées. Nous déconstruirons l'ensemble Refroidisseur intermédiaire FAW assembly and its 36 composants réparables, including the cooler core, the debris grille, all associated ducting and piping, and the complex, vibration-isolating bracket system.

Composant principal: The Intercooler Assembly (1119010-90U)

The heart of this system is the ‘Intercooler Assembly’ (1119010-90U), qui est le principal Refroidisseur intermédiaire FAW cœur. 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 Refroidisseur intermédiaire FAW. Ce “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,” et le Refroidisseur intermédiaire FAW is the component that makes it efficient. A clogged or leaking Refroidisseur intermédiaire FAW will result in a severe loss of engine power, high black smoke, et une mauvaise économie de carburant.

The Protective Grille (1310050-90U)

The ‘Grille assembly’ (1310050-90U) is the primary protective component for the Refroidisseur intermédiaire FAW. 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 Refroidisseur intermédiaire FAW. 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 Refroidisseur intermédiaire FAW, 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 Refroidisseur intermédiaire FAW and preventing it from doing its job. This grille assembly ensures the Refroidisseur intermédiaire FAW core remains clean and protected.

Le “Hot Side” Piping: Turbo to Intercooler

Le “hot side” de la Refroidisseur intermédiaire FAW 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’ (1119062-74UN), 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 Refroidisseur intermédiaire FAW 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’ (1119055-74UN) 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 Refroidisseur intermédiaire FAW système.

Le “Cold Side” Piping: Intercooler to Engine

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

This part of the circuit includes the ‘Intercooler outlet pipe assembly’ (1119031-91W), 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’ (1119127-91W).

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) est un élément clé du Refroidisseur intermédiaire FAW assemblée.

Le “Soft Mount” Bracket and Stay System

Le Refroidisseur intermédiaire FAW 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’ (1302040-91W), which isolate it from vertical road shocks.

L'ensemble Refroidisseur intermédiaire FAW and radiator assembly is held in place by a complex set of brackets:

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

To control fore-and-aft movement, the system uses four ‘Tension rod flexible cushion assembly’ (1302050-01) unités. 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 Refroidisseur intermédiaire FAW‘s long-term reliability.

FAW Intercooler Logic Assembly Parts List

Le tableau suivant fournit l'intégralité, ventilation détaillée de tous 36 components identified in the ‘Intercooler, Grille, Piping, Support’ schéma du tracteur FAW CA4251P66K24T1A3E5. This entire Refroidisseur intermédiaire FAW system is critical for engine power.

Spécifications techniques et contexte d'assemblage

Les spécifications pour le Refroidisseur intermédiaire FAW 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. L'ensemble Refroidisseur intermédiaire FAW logic assembly is critical for performance.