When I posted an inquiry on South African grill removal earlier this
month several listmembers suggested that I post a summary of hints
received and my experience with them.

I tackled the job Saturday, taking advantage of the sunshine and
temperatures in the high 50's we have been enjoying lately.  I also used
a hair dryer on the grill plastic just to make sure it was warm enough to
be flexible.  I started with the outside corners, with some firm hand
pressure and gentle persuasion with a paint scraper (covered with a rag
to protect the finish) wedged between the grill and bodywork, the press
fit mounting studs eventually popped loose.  For the inboard two mounting
studs I peeled the grill away from the body work as carefully as I could
until I had space enough to stick a long screwdriver in back there and
wedge open the metal "spring" halves (that keep the mounting studs
secure) enough to let the remaining mounting studs pop free.

Before reinstallation I made a few changes:

-  I installed a mounting stud, the kind you turn 90 degrees to lock, in
the center location on the SA grill.  The SA grill as purchased did not
have any mounting stud in that location, but did have a hole in which to
put the one I salvaged from my old stock Vanagon grill.

_  I inserted a screwdriver into the outer four mounting receptacles on
the body work and gently spread the spring halves in each one a little
farther apart so that the studs would pop free a little easier next time.
 I did not touch the center receptacle as I wanted it to still be tight
as I would be using the turn to lock stud in that location.

-  Lastly, I greased the outer four studs and receptacles where they
contact each other.

The grill is still secure, but can be removed MUCH easier now.

Thanks to all who responded with suggestions.

Best wishes,

Tony

Anthony L. Mourkas
Hampden, Maine, USA
1984 Vanagon Westfalia
1987 Vanagon GL Syncro
1991 Jetta Eco Diesel