Nissens 96842 Intercooler - Front

Nissens 96842 Intercooler for Sprinter

The Nissens 96842 intercooler is a specific-fit, OEM-equivalent replacement built with an aluminum core and plastic tanks for controlled charge-air cooling. It is engineered for 2003 Dodge Sprinter 2500 and 2003 Dodge Sprinter 3500 applications, excluding low emission engine models.

Key Features

• Specific-fit intercooler for direct application matching
• Aluminum core with brazed cooling fins for efficient heat transfer
• Plastic inlet and outlet tank construction
• Straight outlet type
• Core dimensions: 28.27 in. length, 10.20 in. height, 1.26 in. thickness
• 2.56 in. inlet and outlet outside diameter
• OEM-equivalent grade from Nissens

Detailed Description

Nissens 96842 is a replacement intercooler developed for charge-air cooling in select Dodge Sprinter diesel applications. By reducing intake air temperature after turbocharging, the intercooler helps maintain consistent airflow density and supports stable engine performance under load. This part cross-references 2D0145805 and 718114 for the same application. Nissens applies its thermal-component manufacturing focus to this intercooler, using an aluminum core with brazed cooling fins and plastic end tanks to match the intended OE-style layout.

Compatible With 2003 Dodge Sprinter 2500 and 2003 Dodge Sprinter 3500, this Nissens 96842 intercooler is a direct-fit option for owners replacing a damaged or leaking charge-air cooler on these vehicles. It is not for low emission engine models.

What It Helps Address

• Boost pressure loss caused by intercooler leaks
• Reduced charge-air cooling from damaged fins or core fatigue
• Cracked or deteriorated plastic tanks
• Heat-soak issues that can affect intake air temperature control
• Fitment problems from using the wrong Sprinter intercooler configuration

Installation Notes and Tips

Verify the inlet and outlet diameters, core dimensions, and outlet style before installation. Inspect charge pipes, clamps, and seals for wear so the replacement intercooler can seal properly. Confirm engine emissions configuration on the vehicle, since this part is not for low emission engine models. Professional installation is recommended for proper alignment and leak-free operation.

Quality Assurance

Nissens develops thermal and engine-efficiency components for the aftermarket with an emphasis on OE-equivalent construction and application-specific fitment. The 96842 intercooler reflects that approach with a specific-fit design for 2003 Dodge Sprinter 2500 and 2003 Dodge Sprinter 3500 models.