Mercedes G Class Diesel Cooling Kit

G-Class Heavy Duty Cooling System

The Overland-G Heavy Duty Cooling Package provides a complete thermal management system for Mercedes G-Class diesel conversion builds.

Thermal Control

The system is designed to maintain stable operating temperatures under sustained load, low-speed off-road driving and high ambient conditions. It addresses one of the key limitations in drivetrain conversions — consistent heat management across multiple systems.

System Components

The package is modular and can include:

• Engine radiator
• Air conditioning condenser
• Water-to-air aftercooler
• Transmission oil cooler
• Power steering cooler
• 800W high-output cooling fan with standalone PWM control

Airflow Design

The system is built around a controlled airflow concept. A removable diffuser directs air through the cooling stack, improving efficiency and reducing heat buildup during slow or technical driving conditions.

This layout ensures consistent performance in environments such as sand, rocky terrain or high-temperature climates.

Multi-System Integration

The cooling package is designed to support combined thermal loads from engine, transmission and intercooling systems. It is particularly relevant for builds using ZF 8HP conversions or water-to-air intercooler setups.

Configuration

The system can be configured with custom temperature sensors and control strategies depending on the vehicle setup. Each configuration is defined based on the requirements of the build.

System Integration

This package is part of the complete Overland-G Diesel Engine Conversion Kit, where thermal management is aligned with drivetrain and electrical systems.

Compatibility

Designed for Mercedes G-Class platforms W460, W461 and W463 with OM612, OM613 and OM648 engine conversions. Compatibility and configuration should be confirmed before ordering.

Application

Used in builds where stable thermal performance is required across engine, transmission and auxiliary systems during continuous operation.

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