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
GM 92184976 - Windshield Cowl, Small
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 (6) of them. 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 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:
Engine bay with cowl removed and clip placement:
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.
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.