Mercedes G Class Water to Air Intercooler Kit

G-Class Water-to-Air Intercooler System

The Overland-G Water to Air Intercooler Kit provides a compact charge cooling solution for Mercedes G-Class diesel conversion builds where space and airflow are limited.

System Concept

Unlike traditional air-to-air intercoolers, this system uses a liquid-based cooling circuit to stabilize intake temperatures. It is particularly effective in environments where airflow is restricted and vehicle speed is low.

Packaging Advantages

The G-Class engine bay offers limited space for frontal intercooler setups, especially when combined with upgraded cooling systems and drivetrain conversions. The water-to-air configuration allows the cooling system to be integrated within the engine bay without relying on large external airflow surfaces.

Engine Compatibility

Designed for OM612, OM613 and OM648 diesel engine applications, the system integrates directly into the Overland-G conversion platform.

Configuration Options

Multiple configurations are available depending on the build:

• Integration with the original intake manifold
• Custom intake manifold with integrated cooling element

This flexibility allows the system to be adapted to different engine layouts and performance requirements.

Thermal Stability

Water-to-air systems provide consistent intake temperature control across varying load conditions. This is especially relevant in off-road environments where airflow is inconsistent and thermal load remains high.

System Integration

The intercooler kit is designed to operate together with the Overland-G Heavy Duty Cooling Package and is part of the complete Diesel Engine Conversion Kit.

Configuration

Each setup is defined based on the vehicle layout, engine configuration and supporting systems. Intercooler specification is matched to the overall build.

Compatibility

Compatible with Mercedes G-Class platforms W460, W461 and W463 as part of diesel conversion builds. Configuration should be confirmed before ordering.

Application

Used in builds where compact packaging and stable intake temperature control are required under continuous load.

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