Guys I need some help and advice

[Zuki Habit]

First of all I'm new here.. Hi everyone.
I have a samurai with a 1.6td that i'm worried i'm going to hurt the engine.

Here is my situation and what i'm thinking.
When I'm running the sammy with no boost it runs between 185 and about 195 this is with an autometer sport comp gauge
When I'm putting some boost to it it will go up to god only knows iv'e seen it as high as 218. this is with 8lbs of boost. That is the most boost that it will make.
I'm running the large Quantum radiator with dual fans

I've been told that this engine will run all day at the governor....That being said when it's running what I think is hot I still have more rpm's to go.
What is too hot for these engines?  Should I install a pyro gauge and where?
It has 12 to 15 lbs of oil pressure at idle when its hot.

Even at full throttle on a climb no smoke...I do have some blowby from the breather in the valve cover which I have vented down under the suzuki.
It runs Great. I just don't want to hurt it. I have a tach but havent gotten it hooked up yet. It reads off the altinator.
I am running 33x 12.50  tires with a 6.5 reduction gear in the t-case and 4.10 ping and pinion also.
Any help would be greatly appriciated.

Bill

[speedy]

Assuming you're talking about water temperature, 218 is not going to cause any immediate problems.  That said, I would still want to find out why it is running warm and fix the problem.  Could be lack of airflow through the radiator, plugged radiator, bad water pump impeller, or air pockets in the coolant passageways.  You might also want to double-check the accuracy of your gauge - easiest way is with an IR pyrometer (available for a reasonable price from Harbor Freight, Sears or Home Depot).  Point it at the water outlet on the side of the cylinder head and verify that it is close to the same reading as your normal gauge.

The Quantum dual fans - the one with the larger motor is a two-speed fan, is it working on the high speed?  If you do a lot of low-speed, high-power slogging/climbing you might want to swap out the thermo switch in the radiator with one that will turn the fans on sooner (at a lower temperature).

As a test, take it on the freeway and run it up to 70-75mph, preferably into a headwind.  Does the temp go up to 218?  If not, you have a fan or airflow issue. 

-David

[Zuki Habit]

The gauge has been calibrated, I know its right. I am picking it up at the back of the head.
I have gotten all the air out for sure. It's a brand new rad.
70 mph is wishfull thinking...lol
The dual fans are manually controlled. Their not stock and they have a nice shroud
The only time it gets Hot is when I'm giving it boost for an extended period of time, like on the freeway. To run 60 i'm pushing 8 lbs of boost

[Turftech]

To run 60 i'm pushing 8 lbs of boost

You definitely have something wrong...  You should be flying with full boost in that little thang.  How's the compression?

[Zuki Habit]

I have alot of gearing in this suzuki. It's really more for off road I'm just trying to get the best of both worlds. The Jetta I took it out of was a little rocket compaired to the zuki.

[Zuki Habit]

Also I'm not running the oil cooler

[Turftech]

I kinda skimmed over the gearing...  Doh!     I know my Jetta gets hot in a hurry when heavy on the boost.  Thats stock too.  I'm thinking the oil cooler will help, but they will get fairly toasty at constant full boost.  Just to confirm though, you are talking about the coolant temp here?  How hot is the head?  Have you cross checked the sport comp gauge with an IR temp gun?  Has it ever overheated?  Does it leak at the water pump at all?  Have you checked the thermostat function?  Are the fans getting unrestricted air and cycling properly? (Might want to have them on constantly while at continuous full boost)  What mix are you using for coolant?  (should be 70/30 max)  Have you used "stop leak" and plugged up most of your rad?  Is the rad clean?  Are there "hot spots" on the rad?  (use temp gun to check)  Is the system properly pressurized?  Have you made sure you don't have an air block in your cooling system?  Is the system over pressurizing? (head gskt)  etc etc etc  Might just be that you need a bigger rad...?

That's just some of the obvious stuff.  Their could be any number of reasons for overheating, so more detail would be good.  Don't really know what all you've tried etc.  Fact is, 218 ain't that hot. 

Eliminate the obvious stuff and you'll probably find the problem. 

[4wheeler]

Fact is that a 33" tire and a box goign down the road taxes the little engine..
The IDI doesn`t breath at all in the higher RPMS. (damn prechamber)
the higher the rpm the higher the temperatures.. More coolant volume in your system in the only way to solve the issue.
AKA bigger radiator.. I have a sidekick with 34 s and had the same issue.
bigger radiator is the only solution.

[speedy]

What RPM are you at at 60mph?  If over 4000rpm, that could be the cause.  The efficiency of the 1.6TD engine starts to drop after 3000rpm and the curve gets pretty steep above 4000rpm.

You may just need a bigger radiator BUT you could also just need more airflow through the current one.  Depending on how your engine compartment is vented, there may be a high pressure zone behind the radiator.  You might try running without your hood once and see if it makes a difference.

-David

[Zuki Habit]

What RPM are you at at 60mph?  If over 4000rpm, that could be the cause.  The efficiency of the 1.6TD engine starts to drop after 3000rpm and the curve gets pretty steep above 4000rpm.

You may just need a bigger radiator BUT you could also just need more airflow through the current one.  Depending on how your engine compartment is vented, there may be a high pressure zone behind the radiator.  You might try running without your hood once and see if it makes a difference.

-David

That is what i'm going to try next..Bigger rad is not an option I have the biggest I can get in there. On paper I think i'm at about 3800 to 4000 rpms at 60..I think I just need to keep it off the freeway.