Windshield cowl documentation

[Executor999]

I know it's been three months since someone posted on this thread but I want to share my intel since I had the exact same problem. I had my windshield replaced in late May. Safelite did a great job with the windshield install but my windshield cowl did not sit flush afterwards. #1, they didn't use new clips and #2 the windshield cowl was damaged as a result of how they removed it. As soon as someone pulls up on the edge that fits flush with the windshield, it's game over. Your cowl is done.

After talking with Safelite they acknowledged the issues. Oddly enough they bought a new cowl but not new clips. I decided to let them use a complete set of clips I had ordered a couple years ago. Everything went well with the install of the new cowl until the next day I tried to use the windshield wiper fluid: no fluid. Obviously the hose was disconnected. I looked for where it was disconnected, found where but couldn't find both ends, so I called Safelite and they told me to some by the shop the same day.

Here's where things went from bad to worse. The tech couldn't connect the windshield wiper fluid hose either because it was next to impossible to see. In hindsight we should have used a mirror but instead, to my dismay, he removed the entire cowl. Fortunately I had a SECOND set of new clips on hand but I certainly wasn't happy that we had to use them. There were a couple of times where the tech started to pry up on the edge that fits flush with the windshield and I stopped him. Unfortunately when it was all done the washer fluid hose was fixed, but only most of the cowl fit flush. A large section of the far end of the drivers side did not. No good.

I decided to remove Safelite from situation. They did a great job on the windshield install but I need to oversee the installation of the cowl myself. Considering how much research I've done, I should have a Master's Degree.

Despite the cost, I ordered a new cowl which is actually two pieces plus the required seal. They cost me $418.31 shipped. For the record, they do not come with new clips.

GM 92215638 - Windshield Cowl, Large
GM 92191077 - Windshield Seal
http://www.danielhower.com/g8/large-cowl.jpg

GM 92184976 - Windshield Cowl, Small
http://www.danielhower.com/g8/small-cowl.jpg


There are three clip types you need to install the cowl:
(6) GM 92138942 (yellow/white)
(4) GM 92138946 (black/white)
(2) GM 92138966 (blue/red)

The fourth clip type (GM 92138627) can be reused. They are solid black and you need (7) of them. (6) go on the top and (1) is used to secure the insulation to the underside of the large cowl. You are most likely familiar with them if you have ever changed out your air cabin filter.

From my own experience GM92138966 (blue/red) is discontinued in the States. The other two clip types are available but they are both very expensive buying from GM dealerships or on Ebay.

This is where OZ Auto Moulds & Rubbers (http://www.ozautomoulds.com.au/c/36/clips-fasteners) in Australia saved the day. The bad news is you have to buy packs of 10 but the good news is the total cost is much cheaper than buying them in the States. It cost me just $62.30 for 30 clips shipped.

To the best of my knowledge here is the correct clip placement:
http://www.danielhower.com/g8/large-cowl-clips.jpg

http://www.danielhower.com/g8/small-cowl-clips.jpg

Engine bay with cowl removed and clip placement:
http://www.danielhower.com/g8/engine-bay-cowl-removed.jpg


I hope this helps others since there is no clear documentation from GM.

I want to thank Crazy Paul and Jeff (aka 08G8V8) for sharing their experience and insights.
http://forum.grrrr8.net/showthread.php?t=23083&p=370068&viewfull=1#post370068

I am planning on installing the new windshield cowl today, for the first time by myself. And yes, despite all this clear documentation I'm nervous as hell. :)

[Markmsf3]

Wow. I'm needing a new windshield myself and now I'm scared they'll screw it up.

[Executor999]

Wow. I'm needing a new windshield myself and now I'm scared they'll screw it up.

Safelite did a great job with the windshield install and I can't blame them for the complex design of this windshield cowl. When I had my windshield installed on my '98 Grand Prix there were no such issues. I just wanted to give everyone else a heads up.

[08G8V8]

That does look like the correct placement, the red/blue in each corner. These pics will be good for anyone else in the future......something I should have done when I did mine!

[Executor999]

Well, I successfully removed the old cowls and replaced them with the new ones. The hardest part is removing the old one. I test fitted the cowls without clips before I committed to snapping them in place. It was a different story when inserted the clips. The jury is still out. It's 50% flush. The driver's side is still not flush and it's catching on something underneath so I will try again soon.

I'm still pretty positive the clip placement is correct because both the blue/red and black/white clips have to travel through more material than the yellow/white clips and thus they have more space between the top of the clip and where they snap into place.

In my research I came across posts on Holden Commodore forums where installing a new cowl didn't always work, even with new parts, and that Holden has a redesigned set of clips that helped some even though they had flaws of their own.
http://forums.justcommodores.com.au/ve-holden-commodore-2006-2013/218449-cowl-panel-not-seating-flush-windscreen.html


I'm defeated for today. :(

[TonyKarter]

So is there a right way to remove the cowl without damaging it and so that it will go back in place correctly with just the clips that it came from the factory with?

[Executor999]

So is there a right way to remove the cowl without damaging it and so that it will go back in place correctly with just the clips that it came from the factory with?

Yes. As long as you don't pull up on the edge that sits flush with the windshield you are fine. It means getting the right metal clip removal tool with some reach, and removing them from the bottom. You can also pull up on the 'bottom' edge of the cowl which is covered by the hood, after you disconnect the hose and remove the 6 solid black clips.

[Executor999]

Something I just noticed is the seal for the cowl side extension is missing on the driver's side. I wonder if this is causing the fitment issues? The seal isn't a separate part as far as I can tell, so I am going to order the cowl extension, assuming it isn't discontinued.


http://www.danielhower.com/g8/cowl-side-extensions.jpg

[TonyKarter]

Excellent! I was beginning to think from what I have read about this cowl on this post and other posts that if it had to be removed it would never go back on correctly. If it is not too much trouble would you please post a link or picture showing the proper long metal clip removal tool that you are describing? Eventually I'll have to do this and when I need that tool it's a 54 mile drive out of these woods to Harbor Freight or Northern Tool. I'd rather buy one online at my leisure and have it on hand for that fateful day.

Now you have me thinking about this, having to replace the windshield. Couldn't we just remove this cowling the correct way before we take our cars in to have the windshield replaced, or is there some windshield re-fitment issue that requires that they immediately reinstall the cowling as part of getting the replacement windshield dead-nuts and positioned on the car precisely?

And THANKS! Great post with pics and part numbers. Your post and others here transcend even the best shop manual.

[Executor999]

Excellent! I was beginning to think from what I have read about this cowl on this post and other posts that if it had to be removed it would never go back on correctly. If it is not too much trouble would you please post a link or picture showing the proper long metal clip removal tool that you are describing? Eventually I'll have to do this and when I need that tool it's a 54 mile drive out of these woods to Harbor Freight or Northern Tool. I'd rather buy one online at my leisure and have it on hand for that fateful day.

Now you have me thinking about this, having to replace the windshield. Couldn't we just remove this cowling the correct way before we take our cars in to have the windshield replaced, or is there some windshield re-fitment issue that requires that they immediately reinstall the cowling as part of getting the replacement windshield dead-nuts and positioned on the car precisely?

And THANKS! Great post with pics and part numbers. Your post and others here transcend even the best shop manual.

Here's the clip removal tool I bought. Wish there were longer ones
https://www.amazon.com/Lisle-35260-Plastic-Fastener-Remover/dp/B0002SRCMO/ref=pd_sim_263_3?ie=UTF8&psc=1&refRID=WCPCVVK6MKRDJC4VP8P0

And yes, I don't see why you can't remove the cowl yourself before the windshield tech arrives to ensure it is removed correctly. Just keep in mind the windshield wiper arms come off and well, if you are driving to a shop, just hope you don't need them. :)

In fact if/when you remove your cowl, please take pics to confirm the types of clips, their quantities and their placement. I am kicking myself for not doing this when Safelite replaced my cowl with new ones two weeks ago.

[-Ray-]

http://uploads.tapatalk-cdn.com/20160925/70156026bcc176adaefee12732e65193.jpg

I'm missing that piece too. Mine sits flat. Body shop replaced my window when they painted it.

[Executor999]

I'm missing that piece too. Mine sits flat. Body shop replaced my window when they painted it.

Hmmm. Either they misplaced yours too or maybe just the passenger's side has the seal to protect the HVAC unit. I ordered one. Hopefully it will reveal the answer.

[TonyKarter]

Oaky, now I know what tool. Found these online at Harbor Freight. http://www.harborfreight.com/paneltrim-removal-tool-set-6-pc-63032.html They LOOK long enough, but I guess it is going to take a long drive to go find out. The front edge looks like it might be too thick to get under the pin, the tool being an upholstery removal tool and not a true pin removal tool. Will have to see.

[Executor999]

Oaky, now I know what tool. Found these online at Harbor Freight. http://www.harborfreight.com/paneltrim-removal-tool-set-6-pc-63032.html They LOOK long enough, but I guess it is going to take a long drive to go find out. The front edge looks like it might be too thick to get under the pin, the tool being an upholstery removal tool and not a true pin removal tool. Will have to see.

Those are the best ones I've seen. Amazon sent me the wrong ones but they were so cheap I didn't complain. Definitely going to go for these; they will be useful for other applications.

[-Ray-]

Air Inlet Grille install. GM only has instructions for RH drive. I talked to the tech and he doesn't remember anything special about installing it. I don't know if it was removed when the windshield was replaced.

Ray

[GXP-G8]

Mine has a piece of plastic there at the end in Rays pic, not a seal.

[Executor999]

Mine has a piece of plastic there at the end in Rays pic, not a seal.

This is what I have too and after the new one arrived, I confirmed it doesn't come with a seal or insulation attached to it.

Safelite came back last week, re-fitted the cowl and confirmed that the cowl is warped. So they are ordering yet another new cowl and new clips. While I just want this to be over, I'm glad I'm no longer throwing more of my own money into a bottomless pit.

[sixt9stang]

I thought I was the only one with a cowl that doesn't sit flush. I figured it was just wrong clips, but you are saying it is just bad? It is very uniform along the windshield and just doesn't seem to want to be pressed down any further.

Sent from my Nexus 6 using Tapatalk

[Executor999]

I thought I was the only one with a cowl that doesn't sit flush. I figured it was just wrong clips, but you are saying it is just bad? It is very uniform along the windshield and just doesn't seem to want to be pressed down any further.

Sent from my Nexus 6 using Tapatalk

Safelite 'mangled' my original cowl when they installed the windshield so they got me a new one, which fit flush the first time it was installed. Unfortunately the next day they had to remove it in order to connect the windshield washer fluid hose (really stupid mistake), and when they re-installed the cowl it no longer fit flush. I dealt with it for a couple weeks then called Safelite to complain. So last week they determined this cowl is warped and justified getting a second new one. The last Safelite technician mentioned windshield cowls are delicate and easy to warp due to either sun damage or being handled too much. He wasn't surprised it didn't fit flush afterwards.

[Markmsf3]

I've read that it's how they yank if off that warps it. I wonder what clips they're ordering. One of the clips is discontinued in the U.S. and one had to be bought in bags of 10. I'm talking to a guy that live in S.Australia to see if they can get the right clips. I need a new windshield, but plan on removing the cowls myself in order to not let some windshield guy yank them off.

[Executor999]

I've read that it's how they yank if off that warps it. I wonder what clips they're ordering. One of the clips is discontinued in the U.S. and one had to be bought in bags of 10. I'm talking to a guy that live in S.Australia to see if they can get the right clips. I need a new windshield, but plan on removing the cowls myself in order to not let some windshield guy yank them off.

From my own experience GM92138966 (blue/red) is discontinued in the States. The other two clip types are available but they are both very expensive buying from GM dealerships or on Ebay.

This is where OZ Auto Moulds & Rubbers (http://www.ozautomoulds.com.au/c/36/clips-fasteners) in Australia saved the day. The bad news is you have to buy packs of 10 but the good news is the total cost is much cheaper than buying them in the States. It cost me just $62.30 for 30 clips shipped.

[Markmsf3]

I'm trying to buy a set of clips from them, but it appears they don't ship to the U.S.. I've sent them a message asking them what's up.

[Executor999]

I'm trying to buy a set of clips from them, but it appears they don't ship to the U.S.. I've sent them a message asking them what's up.

That can't be right. I emailed them and asked if they shipped to the US and they replied yes. I talked to a Michael Bourke, who sent me a Paypal invoice directly. Maybe their ecommerce system can't ship to the US but they made it happen. I placed the order last month.

[Markmsf3]

Yeah, I'm speaking with him now. We have to email him the order as the website does not compute international shipping. I'm buying a set too. I need a windshield and plan on doing the cowls myself instead of just some jackwagon ripping them loose.

[Markmsf3]

The current shipping rate for 10 each of the 3 clips is $55.00, FYI.