Having recently done an oil cooler on an OM642 engine, here’s a quick run down of the parts required. Most gaskets are one use only and is best to have everything as stripping down again is a pain.
Based on a 2014 W212, other models or older variants of the engine may be slightly differently, notably the EGR system and air intake pipe from airboxes to turbo.
Have marked items as required for when stripping right down and going as far as the oil cooler.
Advisable items – see notes
Prices are genuine + vat, as time of post (04.05.26)
Oil Cooler
The star of the show. Never seen an oil cooler leak, just the seals. But would you risk it?!
Item 200, A6421800165, Oil Cooler, £153.00+
Item 210, A6421880480, Oil cooler seal, £3.50+ x2
Note the old number is A6421880180, don’t use these….
Inlet manifolds / Inlet port motor
Item 10, A6420907737, Right intake manifold, £526+
Exchange, A642090773780, £426+
Item 20, A6421500594, Inlet port shut off motor, £229+
These tend to get covered in oil, worth replacing
Item 30, A0139970045, Seal from right inlet manifold to cross charge pipe, £4.90+
Item 40, A6421410580, Right intake manifold gasket, £5.75+
Item 70, A0029900122, Right intake manifold bolt, M7x25, £0.85+ x6
A0029909222, Right intake manifold bolt, M7x70, £2.30+ x2
A0029909922, Right intake manifold bolt, M7x100, £2.35+ x1
Item 80, A6420980037, Connector from manifold to manifold with o-rings, £5.55+
Advise to replace as if it leaks after its strip back down!
Item 100, A6420906637, Left intake manifold, £399+
Item 110, A6420910150, Ball socket, £2.45+ x4
Item 120, A6421410580, Left intake manifold gasket, £5.75+
Item 130, A001990572264, Left intake manifold bolt, M7x40, £2.00+ x4
A0029909222, Left intake manifold bolt, M7x70, £2.30+ x3
Charge Air Cross Pipe (Connects inlet manifolds to throttle body)
Item 170, A6420980180, Seal from charge cross pipe, to left inlet manifold, £11.90+
Item 190, A6421410080, EGR return pipe seal – see my notes about the pipe that mates to this, £6.80+
Item 290, A0079934201, throttle body pipe securing clip, £1.65+
– (try not to loose it… ask me how I know…)
Item 300, A6421410180, Seal from throttle body to cross pipe, £1.35+
– Shouldn’t have to take this off. But your in the area…
Item 340, A0139972345, Noise damper o ring, £2.45+
– Shouldn’t have to take this off. But your in the area…
Turbo / manifold collector area
Item 20, A0009906803, £2.45+ x3, bolt, M8x25, from turbo to collector. Not normally required, as you can take off turbo and collector in one, but just in case.
Item 40, A6421420481, £5.50+, gasket. You can normally get away with not removing the turbo from the collector. But if you do, replace this gasket.
Item 110, A0019903107, £1.75+ x2, bolt, M8x27. Turbo to carrier. Not normally required.
Item 120, A6421420981, £4.40+, gasket. Replace, one time use.
Item 130, N910143008017, £2.30+ x4, bolt, M8x55. Carrier to cylinder crankcase.
Not normally required.
Item 140, A6421420681, £2.85+, gasket.
Replace, one time use.
Exhaust manifolds Area
Item 60, A6421423280, Turbo to right exhaust manifold gasket, £5.05+
Item 160, A6421423180, Turbo to left exhaust manifold gasket, £5.05+
Item 80/180, A00099068013, bolt collector to manifold, M8x25 x5, £2.45+
Replace, you don’t want these to snap when putting it back together.
Downpipe
Item 100, A2194920080, Gasket between turbo and downpipe, £9.05
Item 115, A0009906703, Bolt for turbo to downpipe (seen a few snap, don’t get caught out), £2.60+ x3
EGR System / Pipework
You can remove this as one with the left inlet manifold, however would highly advise cleaning out the pipes that connect to the EGR changeover flap as they can become blocked and create airmass faults.
Item 20, A6421401263, Changeover flap, £107.00+
Item 40, A6421420580, Gasket – EGR Cooler to Manifold, £2.45+
Item 100, A6421402160, EGR Valve, £382.00+
Item 110, A0259973448, EGR Valve seal, £4.25+
Item 120, A6421410680, Seal, £3.05+
Item 160, A2721420480, Seal from EGR line to exhaust £3.45+
Item 170, A6421421880, Seal, EGR Line to valve, £2.85+
Item 220, A6421410080, Seal changeover flap to cross pipe, £6.80+
Item 260, A0189978945, O ring, £2.95+
Item 380, A6421420381, Gasket, £3.15+
Item 310, A0189979045, O ring, £7.00+
Item 400, A6421421081, Gasket, £3.25+
Airmass pipe / boost pipe area
Item 60, Air intake pipe seal, couple of types; Very common to go soft / split. Replace as good measure if OK.
A6420940180, £2.85+
A6420940480, £not sure!
Item 20, A0149976445, Green boost pipe to seal seal, £7.05 (note, these go hard and brittle, remove and check at least)
Oil Separator line seal
Item 110, A6420940580, Seal, £5.25+ – Very common to go soft / split. Replace as good measure if OK.
Bonus bits
Common to wear and make the engine cover rattle;
A0009982342, Rubber mount for engine cover, £1.05+
Replace the coolant thermostat whilst you are there, easy change whilst its all off – Its on the front of the right hand inlet manifold.
A6422002215
Fuel filter rubber line clamps, can be re-used, but sometimes break, two sizes
N000000004732, £2.10+
N000000004683, £0.55+
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