Mercedes Sprinter Intercooler – Hudson | NCV3 3.0L OM642 | #9065010101 (2007–2009)

A cracked, leaking, or internally fouled intercooler on a NCV3 Sprinter allows hot, low-density charge air to reach the intake manifold — reducing power output, increasing combustion temperatures, and in severe cases contaminating the intake system with oil from a failed boost connection. This is the Hudson intercooler for 2007–2009 NCV3 Sprinters equipped with the 3.0L OM642 V6 diesel engine, a direct replacement that restores efficient charge air cooling and full boost performance.

What This Part Does

The intercooler — also called a charge air cooler — is a heat exchanger positioned between the turbocharger outlet and the intake manifold. Compressed air exits the turbocharger at significantly elevated temperature, reducing its density and the amount of oxygen available for combustion. The intercooler routes this compressed air through an aluminum core where ambient air flowing through the front of the van absorbs the heat, cooling and contracting the charge before it enters the cylinders. Denser, cooler charge air allows the engine to combust more fuel per cylinder per cycle — producing more power and reducing thermal stress. When the intercooler develops an internal crack, a failed end-tank seal, or core damage from road debris, boost pressure drops and charge air temperature rises — causing power loss, increased black smoke, and under-boost fault codes.

Common Symptoms of a Failing Intercooler

• Loss of power or sluggish acceleration under load, particularly at highway speeds
• Black smoke under hard acceleration from reduced charge density causing incomplete combustion
• Boost pressure fault codes or under-boost codes from the ECU
• Oil contamination visible in the intake tract or intercooler pipes
• Visible cracking, oil weeping, or physical damage to the intercooler core or end tanks

When to Replace

Replace when a pressure test confirms boost leakage at the intercooler, when cracking or damage is visible at the core or end tanks, or when oil contamination is found in the charge air circuit. Always inspect and replace the intercooler inlet and outlet hoses and clamps at the same time — a new intercooler on degraded hoses will leak at the connections.

NCV3 OM642 Specific — VIN Verification Required

This intercooler is for 2007–2009 NCV3 Sprinters with the 3.0L OM642 V6 diesel engine. It is not the same unit as the 2010+ BlueTec intercooler (9065010201). Always verify by VIN and confirm the existing part number before ordering. Contact us and we'll confirm fitment before you buy.

Fitment

• 2007–2009 Dodge Sprinter 2500 / 3500 – 3.0L OM642 (NCV3/W906)
• 2007–2009 Freightliner Sprinter 2500 / 3500 – 3.0L OM642 (NCV3/W906)
• 2007–2009 Mercedes-Benz Sprinter 2500 / 3500 – 3.0L OM642 (NCV3/W906)

✔ 2007–2009 only — 2010+ BlueTec models use a different intercooler (#9065010201)
✔ Always inspect and replace intercooler hoses when replacing the core

Part Numbers

• Mercedes OEM: 9065010101 / A9065010101 / 906-501-01-01
• Cross-reference: 68013636AA / 68014095AA / 2E0145804
• Manufacturer: Hudson
• SKU: 9065010101H