Windshield Cowling removal.

It might be a good idea to clean out the track with an old tooth brush. Even with some silicone grease applied to the tongue on the underside of the cover, I eventually filed off some of the tongue which helps reinstalling it. Do not pound it back into place, and that includes your hand. I did not see any mention of the plastic pieces that fit into the upper corner of each fendor; those have to be removed prior to removing the cowl cover.

Cowl Removal

I have two questions about this proceedure. I have a '05 Passat. Just did it last week. Came off fine, but:
1.) I broke the plastic cowl in half about right in the middle. Cracked all the way through. Where is the best palce to get a new one? Dealer? Can I just leave it be with a crack?
2.) I was worried about crossing up the splined shafts on the wipers. However, I just put them on lined up with tape marks on the windshield and tightened them up. What's the odds I have messed up the splines?

If the wiper arms realigned with your tape marks you should be OK. I doubt very much that you crossed up the splines. There should be a part # on the underside of the cowl cover; I would do a google search on that number.

Get the cowl piece from a dealer as I tried to order one from 1stVWparts.com and they were afraid to ship it (breakage). I broke mine, put it back on and used a bead of clear silicone sealant in the crack. So far, so good.

... I only have 1995 & 2002 Jetta experience but...

aja8888 said:

Get the cowl piece from a dealer as I tried to order one from 1stVWparts.com...
and they were afraid to ship it (breakage).
I broke mine, put it back on and used a bead of clear silicone sealant in the crack. So far, so good.

Click to expand...

"aja8888",
Normally I would agree with you and not hesitate to try and fix the cracked plastic cowling
thinking it would cost ~$100!?
.....
I recently also broke my Son's 2002 Jetta's cowling exactly as was described above,
but I readily repaired without even checking to see what the co$t/availability was through the local dealer/stealer(s).
.....
But I'm also proficient at making repairs to plastic pieces...
inside trim as well as exterior.
.....
But then later I was at 1 of 3 Dealer's taking care of a Recall issue to kill time I went to the Parts Dept.
and priced the cowling for this 2002 Jetta... and IF my memory serves me well,
it was less than $35.00 before taxes.
.....
Realize at a different "Stealer" dealership, then price could very well be inflated considerably over this...
what I consider to be a very reasonable price.
.....
IF you want to learn a little about plastic repairs and consider repairing your crack/break, let me know by this FORUM's PM for I think I have some photos I can share!
My repairs for such entails use of reinforcing the break area with ABS sheet plastic from a local craft shop us gluing/bonding the two together...
while holding the two firmly together with spring clamps for several hours.
Regards,
Sam Ross

Broken windshield cowl

I did effect a plastic repair using super glue and accelerator on the top side. Should have done it from the bottom as it left a whate haze that is objectionalble.

My usual plastic rfepair would have been to clean it with degreaser, spray with a little super glue accelerator, place a swatch of fiberglass cloth bridging the crack on the bottom and drip super glue on the fiberglass until saturated. That really is a strong bond and lasts forever, bur looks bad so you must do it from the back.

Wonder what you have tried in the past?

I think I'll buy a new one if they are under $50.

John

brock71 said:

I did affect a plastics repair using super glue and accelerator on the top side.
Should have done it from the bottom as it left a whate haze that is objectionalble.
My usual plastic repair would have been to clean it with degreaser,
spray with a little super glue accelerator,
place a swatch of fiberglass cloth bridging the crack on the bottom and
drip super glue on the fiberglass until saturated.
That really is a strong bond and lasts forever,
bur looks bad so you must do it from the back.
Wonder what you have tried in the past?
I think I'll buy a new one if they are under $50.
John

Click to expand...

John,
On plastics breaks in flat pieces like the cowling, I find that ABS
plastic sheeting works well.
I pick up the sheets that are about
6 different thicknesses and use either "super glue"(Isocyanate)
or ordinary plumber's glue for ABS. Both of these glues/chemicals
literally "fuse" the original and reinforcing layers of plastics
and it is very strong.
This is my method where there is room on the backside to
put the reinforcing layer without it showing!
On breaks in "not-so-flat" pieces, I can often use the thinnest
ABS sheets and literally either encase the broken piece in new
layer of ABS plastic using a "heat gun" that reaches ~700-to-1,000
deg.F.
Breaks where it is in full view and it is desirable to have the surface
look well/or/new... these offer the greatest challenge!
Once I made structural repairs to what was a $300 (if replaced)
kick panel that was not the same color as we needed...
this on a Mercedes... and once the plastics repair was finished,
we color matched the paint at a paint store that custom mixes
aerosol cans that is formulated for plastics!
This worked out fair well and cost less than $50...
but this was on a panel that is on the bottom of the dash!
Sam Ross

Windshield Cowling Wiper Valence Removal

Thanks to all who posted on removing this piece of trim plastic..it made the difference in me being able to fix the water leak in through the electrical entry. I made some photos...now to figure out how to post them..

Breaking windscreens? I always use my fingers, never go near the thing with a screw driver.

Anyway here's some handy pics, I did a little how to for removing the ecu on a UK forum I'm on.

http://uk-mkivs.net/forums/p/494434/3400743.aspx#3400743