Neil, it sounds as though you're in too high a gear and lugging your motor.

Third gear at 25 MPH is too slow and will build a lot of heat in the motor.
In my 1.9 if I can't maintain 45 MPH in third I do 25 MPH in second.

Try second gear at 25 MPH (40 KPH) instead.  The motor is in a stronger
place and by turning faster will pump more cooling air past the cylinders.

There's no hurry anyway, right?  :)

Seeya, Jake

On 8/28/07, neil N <musomuso@gmail.com> wrote:
>
> Hi all.
>
> Am in Republic WA right now.
>
> Through *really* steep Colville forest hills, head temps stay at 475 F at
> 40-45 km's in 3rd gear. Oil level is fine and oil consumption much less
> than
> half a litre in over 1700 km's.
>
> I was reading gauge incorrectly. (D-oh!) What I thought was 400 F on steep
> hills, was actually 450 F. On level road, my Westy used to stay at 350,
> but
> is sometimes higher now. Sometimes 400 F or over. (may be windy conditions
> forcing engine to work harder)
>
> I replaced VDO temp sensor after damaging first one when re- installing
> spark plug on #3 cylinder. I used old temp sensor ring as washer to help
> plug turn on washer and not twist sensor while turning plug. Reason
> original
> ruined. Head temps were high, so removed "washer" thinking plug sitting
> too
> "high". New sensor wire got a little chewed again so may not be sending
> correctly.
>
> Question:
>
> IF sensor sending correctly, is 475 F on *steep* hills, too high?
>
> Any other way to judge if engine too hot? (feeling dipstick etc.)
>
> Engine runs fine otherwise.
>
> Many thanks,
>
> Neil.
>
> --
> Neil Nicholson. 1981 Air Cooled Westfalia -
> "Jaco"  (Bustorius)
>
> http://web.mac.com/tubaneil
>
> Please send me your Vanagon/Westfalia links!
> http://vanagonlinks.googlepages.com/home
>

--
Jake
1984 Vanagon GL
1986 Westy Weekender "Dixie"
www.crescentbeachguitar.com