Retrofitting a solar sun roof

[The_Laird]

Is this possible? I talked to a sun roof company in East Kilbride and they said not. Lots of chat about the factory fit requiring a tool to bend the lip over the sun roof and welding. I'd like to get it done, but don't want to spend a fortune I can get hold of a solar roof fairly reasonably) and don't want to either leave a mess or a leaky roof.

[IT]

Yes, very do-able..... I've done at least half a dozen solar roof retrofits +++

[PsYcHe]

I think they're assuming you don't have a sunroof at all at the minute... It's a swap. Just some electrickery bits needed.

[The_Laird]

I told them that I already had a sun roof. Any recommendations for getting the job done?

[PsYcHe]

Depends how soon you want it done... If we have a write-up, pretty sure I could help you with it.

[notorious]

Yes, very do-able..... I've done at least half a dozen solar roof retrofits +++

Hi Ian,

I wonder if we need to completely remove headliner from the car to do that? Or do we just drop headliner, so two people work from sides of the car to swap stuff?

Love the idear of solar sunroof, but my car is light silver color and I don't think black hatch will look pretty on light coloured car. So I'm undecided.

Thanks.

[IT]

Need to drop the linig at the front a little to route cables. No need to remove.

I'm intending to do a write up when I do tintins Final edition, which is never going to happen unless the weather would make its mind up.

I think its a cool (sorry bout the pun) addition to any 8. It works well with dark paints as it blends in, but with light colours its an awesome contrast and real talking point.

I'd have a solar roof over a solid one any day.... A glass one however is really nice, and more hassle to convert, so I'd be tempted to leave them as they are +++

[Adrian E]

I believe PF and fl solar roofs are different - not sure if the difference is enough to mean they're not interchangeable?

[IT]

Pre and post facelift are the same.

There was a revision in 2001 which saw a different panel with more solar cells on it, but the older one works just fine.....

[HPsauce]

Love my solar sunroof. :love:
Don't really notice the contrast as it's fairly reflective and my car is neither too light or too dark - agate grey.
But as you mostly see a car from the side you don't really ever see it anyway. :cool:

[notorious]

Thanks Ian.

When we retrofit sunroof to FL D2 car with existing "classic" sunroof we just change the "hatch element" or the complete frame with rails, etc?

[IT]

Its easiet just to change the hatch element, ie the sliding panel, and the top half of the rails, leaving the bulk of the frame where it is.

The only difference in the rails is that for solar, the rails have a contact at the end of each rail - 1 plus, 1 negative but as the top of the rails unscrews with simple torx, you can dismantle in situ and swap. Much easier than stripping the whole headlining, and changing whole frame, which is also an option, but harder work.

Interestingly, the D3 sunroofs come with the contacts on the rail whether you have Solar or not.....

[notorious]

Thanks again Ian, very interesting.

I think I will merge sunroof retrofit with retrofitting heated windscreen as heated windscreen has also an electrical connection from the roof side.

[The_Laird]

Depends how soon you want it done... If we have a write-up, pretty sure I could help you with it.

I'm not in any real hurry. I'll buy the sun roof and see if we can find a slot to fit it that suits.

Help would be very much appreciated +++

[Adrian E]

Pre and post facelift are the same.

There was a revision in 2001 which saw a different panel with more solar cells on it, but the older one works just fine.....

Bummer :( I turned down a PF solar roof as when I looked into it with the help of a local specialist we could see a different part number for the age of car the roof was coming out of compared to mine and assumed, without both in hand, that there was a significant difference that would make it expensive to find out whether it would fit by trial and error....

[IT]

Thanks again Ian, very interesting.

I think I will merge sunroof retrofit with retrofitting heated windscreen as heated windscreen has also an electrical connection from the roof side.

Hmmm, heated windscreen also has connections that go behind dashboard. Its the one retrofit I'd never tackle, mainly as you need to remove the windscreen (or have it removed if you're not an expert at it) then spend several hours running wires, then have the new windscreen fitted.... Not really an Autoglass job. I suspect it might even need the dashboard out really, but never seen a car with glass out, but dash still in to see what accessibility is like....

[IT]

Bummer :( I turned down a PF solar roof as when I looked into it with the help of a local specialist we could see a different part number for the age of car the roof was coming out of compared to mine and assumed, without both in hand, that there was a significant difference that would make it expensive to find out whether it would fit by trial and error....

All the roof panels, glass, solid, solar, pre / post facelift are exactly the same size and shape and fitment.

Solar ones have wires, solid ones dont.

Glass ones are the same fit, but have a different interior trim as the roof trim panel on a glass sunroof slides independently of the sunroof itself, so its more complicated to change.

Its not getting the right panel thats the issue really. Its getting the wiring too. The wiring isnt mega special - But - it all runs down to a relay, and a fuse at (iirc) is 40amps as it has to be able to handle all the current for the blower motor - Its chunky cable, and I prefer to lift the whole circuit out in one piece, so it all clicks straight in factory spec. If you dont have all the wiring, you need to source relay, fuse, cables etc......

I can see I need to do this write up....

Donations accepted .... :p

[PsYcHe]

There's enough space with window out to get in behind the dash and pass wires up. Might not be OEM tidy, but certainly decently enough tidy. You'd be surprised how much the window covers of the dash :)

No problem Jim, looked into how it fits on ELSAWin, and it's not that scary looking.

[Adrian E]

I'm getting seriously tempted to do this swap on mine if a suitable roof comes up - being a bit retarded on this front I want a post 2001 panel so it's 'right' for the year of the car, even though it makes no functional difference at all :ROFL:

Ian - is there a list of bits or at least some pics of what you need from a scrap car?

Cheers

Adrian

[Dave McB]

said sunroof place in East Kilbride doesnt really do much......not many sunroofs nor alarms (what they advertise for)

would be interesting to see a solar sunroof, altho, in Glasgow.......would it be any use??....

[PsYcHe]

Still worth it in Glasgow... keeps the edge off the heat for those 3 days we get the sun :)

The Laird will let us know soon enough when we get round to finishing the job off.

[goglawrie]

On that note when as i need you vag test as still parking sensors let me now thanks

[sloss]

On that note when as i need you vag test as still parking sensors let me now thanks

Is that in code? :D

[Dezzy]

Is that in code? :D

:ROFL: that or a good drink has been had.

My solar no longer works as i found out the other day when i got in it. Where should i be looking for the relay is it in the pass footwell? It's only when it stops you realise how good it is eh?

[tintin]

Its not getting the right panel thats the issue really. Its getting the wiring too. The wiring isnt mega special - But - it all runs down to a relay, and a fuse at (iirc) is 40amps as it has to be able to handle all the current for the blower motor - Its chunky cable, and I prefer to lift the whole circuit out in one piece, so it all clicks straight in factory spec. If you dont have all the wiring, you need to source relay, fuse, cables etc......

I can see I need to do this write up....

Donations accepted .... :p

...as it proved in practice with mine. All done now though, thank's to Ian's perseverance, patience, and perfectionism, and some understanding from his family over a couple of weekends. I'm really pleased with it, and it was working nicely for the meet at Haigh Hall - before the return to the normal summer monsoon weather in Manchester. Thanks Ian - I can't think of any other mods I'd like done at the moment ;)

[Adrian E]

Thought I'd post some pics of the spare solar panel I'm stripping ready to fit to my car, to go with Ian's excellent pics of the wiring side of things. Will add them as I go, along with some simplified info on fitting.

These are the clips you need to release to push the fabric internal cover back - they only need finger pressure to release them and there's one each side on the front edge. Sunroof needs to be slightly open to access them and you can then slide it back out of the way

http://i5.photobucket.com/albums/y180/BX16VALVE/Audi%20S8/Solar%20sunroof%20retrofit/D7E655B5-79EB-4919-8702-0F10C592D9AA-214-00000026D5B32DF2.jpg

This is how I got my panel - the whole thing complete with frame! At least it was protected in transit

http://i5.photobucket.com/albums/y180/BX16VALVE/Audi%20S8/Solar%20sunroof%20retrofit/C6C33D79-AF08-43EA-B02D-22E7A509ED95-214-00000026DF73488F.jpg

With the interior trim pushed back this is what you see on a solar equipped car. This is the offside one - it appears when it was assembled they weren't all that careful as the wire is bent and the insulation is slightly damaged. Probably doesn't matter but will check it properly before fitting.

http://i5.photobucket.com/albums/y180/BX16VALVE/Audi%20S8/Solar%20sunroof%20retrofit/8F605B9C-7B3B-490D-8E3B-846B5EC2B86D-214-00000026E30A3E31.jpg

Passenger side view

http://i5.photobucket.com/albums/y180/BX16VALVE/Audi%20S8/Solar%20sunroof%20retrofit/2116F658-BBC6-489B-872A-AC303FB8CE3F-214-00000026E6F14E45.jpg

The 'inside' view of the sunroof trim panel clips so you can see what it is you're unclipping - I just removed this one so I could see how it goes together - I don't need it as it's a different colour to mine

http://i5.photobucket.com/albums/y180/BX16VALVE/Audi%20S8/Solar%20sunroof%20retrofit/EE7CD903-6B2D-4879-94AB-8166564DD814-214-00000026EA17BCA3.jpg

http://i5.photobucket.com/albums/y180/BX16VALVE/Audi%20S8/Solar%20sunroof%20retrofit/5A09604E-127C-48E3-B4CA-11FFD6DBB1F4-214-00000026EE1799E6.jpg

Trim panel out and this is the inner workings of the solar panel itself

http://i5.photobucket.com/albums/y180/BX16VALVE/Audi%20S8/Solar%20sunroof%20retrofit/9C3A9517-3580-43D4-9A4E-C457573FBCFF-214-00000026F1E68F7F.jpg

With the roof panel shut, there are a total of 6 T25 torx screws to remove. 1/4" socket set gave plenty of access. I inverted the panel and undid the screws and lifted the frame off as I was working on my own and didn't fancy dropping it!

http://i5.photobucket.com/albums/y180/BX16VALVE/Audi%20S8/Solar%20sunroof%20retrofit/7BB161FA-30CE-4689-9E79-E2AC626C98C5-214-00000026F5A332CB.jpg

These are the remaining bits you need from the donor car

http://i5.photobucket.com/albums/y180/BX16VALVE/Audi%20S8/Solar%20sunroof%20retrofit/7CC08496-F6F0-49EC-A63A-138A66899F23-214-00000026F96DF26A.jpg

Close up view of the bit that actually does the work - the rectangular block is the contact between the solar panel and the wiring in the frame

http://i5.photobucket.com/albums/y180/BX16VALVE/Audi%20S8/Solar%20sunroof%20retrofit/2BC900D9-BD0C-4E3D-8A8C-A5F5024DB79E-214-00000026FDB16CA7.jpg

E-markings on the glass - E11 is UK and E1 is Germany and Reg 43 relates to laminated glass

http://i5.photobucket.com/albums/y180/BX16VALVE/Audi%20S8/Solar%20sunroof%20retrofit/8B196A5C-80D6-4E5B-ADFC-5255A97308BE-214-000000272082DA1E.jpg

Top view of the panel off the car

http://i5.photobucket.com/albums/y180/BX16VALVE/Audi%20S8/Solar%20sunroof%20retrofit/4A93C06A-1BB1-4D19-85DC-1CA27A6F8A4A-214-00000027246A8C01.jpg

Quick clean with Fast Glass later and the top side looks like new :)

Any tips from the detailing fetishists on how to clean the seal around the sides of the panel? It's more of a felt material than the rubber on the non-solar panels and I nearly fell off my chair when I priced up a replacement!! Thought if it was cheap and available I'd swap it anyway but that ain't happening :o

That's progress so far - will take some pics of the rails as I get them off. Any tips from anyone that's done it before? It looks like the wires go through the frame so no idea if there's a connector I'll see when I've undone the torx screws, or will I have to cut and rejoin the wiring?

Adrian

[briang9]

I used Turtle Wax Restorative Black Bumper & Trim Wax (http://www.autoexpress.co.uk/car-news/29622/turtle-wax-bumper-and-trim-wax) on mine Adrian, came up really well and seems to be lasting well too+++

[47p2]

A steam cleaner and a small brush will bring the seal up like new

[The_Laird]

That's progress so far - will take some pics of the rails as I get them off. Any tips from anyone that's done it before? It looks like the wires go through the frame so no idea if there's a connector I'll see when I've undone the torx screws, or will I have to cut and rejoin the wiring?

Adrian

There's a connector above the rear view mirror IIRC. You'll need to remove trim above the doors (remove front and back grab handles first) to feed the wires through. You can feed the wiring down the trim at the side of the windscreen, unless you insist on going the same route as the original which is then along the top of the o/s front door, down the B pillar, back towards the driver's footwell......

[Adrian E]

Manufacturing info from solar panel

http://i5.photobucket.com/albums/y180/BX16VALVE/Audi%20S8/Solar%20sunroof%20retrofit/518D8EDE-AF8A-46AC-ADEB-35829E0B4381-214-0000003E4199E71A.jpg

Offside wiring - just cable-tied to sunroof mechanism with some anti vibration foam round it

http://i5.photobucket.com/albums/y180/BX16VALVE/Audi%20S8/Solar%20sunroof%20retrofit/283CF191-48EA-4159-9274-45C5891B2294-214-0000003E46A8EBFB.jpg

http://i5.photobucket.com/albums/y180/BX16VALVE/Audi%20S8/Solar%20sunroof%20retrofit/C2EB1DD0-A0E3-4894-9BC4-42638692DFE9-214-0000003E4C04E828.jpg

Nearside wiring

http://i5.photobucket.com/albums/y180/BX16VALVE/Audi%20S8/Solar%20sunroof%20retrofit/81418D9A-C48F-49F3-AF0C-3AF5001C8BDD-214-0000003E50ED9386.jpg

http://i5.photobucket.com/albums/y180/BX16VALVE/Audi%20S8/Solar%20sunroof%20retrofit/5D766CAF-E60D-4E01-9DBD-DCD0C5DCFD3D-214-0000003E563E57B4.jpg

Sunroof motor removed off donor assembly - think the wiring plug should sit in the plastic clip that the wiring is sitting in in the picture

http://i5.photobucket.com/albums/y180/BX16VALVE/Audi%20S8/Solar%20sunroof%20retrofit/898CEA21-9BBD-4CCA-87AB-BD59784B5ED9-214-0000003E5C001A20.jpg

Frame part number details

http://i5.photobucket.com/albums/y180/BX16VALVE/Audi%20S8/Solar%20sunroof%20retrofit/5253F520-B907-4828-9934-CD9703BA8546-214-0000003E66E79EDC.jpg

Wiring ready for removal

http://i5.photobucket.com/albums/y180/BX16VALVE/Audi%20S8/Solar%20sunroof%20retrofit/422DBEFF-FE83-4627-8FEF-5D480BEEC2F6-214-0000003E6B55A488.jpg

Contact point removed from end of sunroof rail - there's is nothing to disconnect the wiring at this end

http://i5.photobucket.com/albums/y180/BX16VALVE/Audi%20S8/Solar%20sunroof%20retrofit/422DBEFF-FE83-4627-8FEF-5D480BEEC2F6-214-0000003E6B55A488.jpg

http://i5.photobucket.com/albums/y180/BX16VALVE/Audi%20S8/Solar%20sunroof%20retrofit/D25347C2-7EEF-410F-8D0B-80FBD3FA3B7C-214-0000003E7B921285.jpg

Having established there's no other way to remove the wiring, this plug needs to come apart. Remove the purple cap with a screwdriver and insert a screwdriver up the end of the plug to press the metal tab on the wire down and pull out the back

http://i5.photobucket.com/albums/y180/BX16VALVE/Audi%20S8/Solar%20sunroof%20retrofit/DBD5063F-4C2F-4252-8BBE-772C0B749D75-214-0000003E80D28CCB.jpg

Contact points top and bottom

http://i5.photobucket.com/albums/y180/BX16VALVE/Audi%20S8/Solar%20sunroof%20retrofit/404D3CA5-EB0E-4AC0-916B-2A57953B454D-214-0000004113259637.jpg

http://i5.photobucket.com/albums/y180/BX16VALVE/Audi%20S8/Solar%20sunroof%20retrofit/E273B5CB-0EA4-4182-B9F9-D174FE38C6D4-214-0000004117D3AD40.jpg

This is the tab you need to free off to get the wires out of the plug

http://i5.photobucket.com/albums/y180/BX16VALVE/Audi%20S8/Solar%20sunroof%20retrofit/8C31251C-650E-404A-A91A-44EC826A030C-214-000000411D02A115.jpg

I didn't take any pics of removing the rails, but basically it's 7x T20 torx on each side and the roof mechanism needs to be more or less right back so the panel mounts are out the way and they can be lifted out.

The screws have evidence of threadlock on them and are barely even finger tight - I had a bit of a play around and it's very easy to over-tighten them and the roof mechanism will then feel tight if you operate it by hand (4mm allen key in motor)

Given the suggested torque for the screws holding the sunroof panel on is 4.5Nm I'd expect the rails don't need to be any tighter than that. If you have it some threadlock probably won't go amiss, particularly on the rails.

I've wrapped the solar panel in bubble wrap for now and won't be fitting it until I have some help available to lift it into place. In the meantime I'm hoping to grab an anti-dazzle mirror as wiring that in properly will involve removing all the same bits of trim as getting the sunroof wiring into place!

Adrian

[HPsauce]

I'm hoping to grab an anti-dazzle mirror as wiring that in properly will involve removing all the same bits of trim as getting the sunroof wiring into place!
Maybe not that difficult. :cool:
I know the FL is different around the mirror area to PF, but I just wired my auto-dim mirror into the sunroof circuit quite simply (comments on a thread somewhere) and the only trim I removed was the cover to the sunroof mechanism that you remove to wind it manually.
Can't recall exactly what wiring I found up there, but IIRC there was one +12V wire that was basically live with ignition on (though possibly stayed on for a brief period afterwards to facilitate closing).

[Adrian E]

True, but I recall Ian saying that to wire it as per factory it needs a reverse feed to cancel dimming, which I quite like the sound of having. Fingers crossed the actual wiring isn't that challenging to find :)

[Architex_mA8tey]

I think youre right Adrian, its another example of the wiring being in place as standard for most add on options on the PF but not for the FL where bespoke looms were fitted dependant on the spec ordered

[HPsauce]

In this case the PF didn't have the wiring either, so I had to be inventive. ;)
I didn't bother with the reverse feed and I struggle to think of circumstances where it would have any use.

[Night Train]

I think that they were only 'pre-wired' up to 1997 in PF flavour....

My '98 PF isn't either...

I'm sure Ian will know....

[The_Laird]

Definitely not prewired in a 2002 model. I've got an auto dimming mirror ready to go in, but I'm just planning live from the sunroof and earth (sorry Ian!)

[IT]

I think that they were only 'pre-wired' up to 1997 in PF flavour....



Correct.... 1997 onwards your A8 loom will be specific to your cars factory options only.... +++

[notorious]

OK, I sourced my sunroof from Germany and will start my retrofit soon.

In a car with solar sunroof there is a hole in the tray for a sunroof wire.
Can I expect to have the same hole in the tray of a car without solar sunroof?

http://forum.a8parts.co.uk/attachment.php?attachmentid=7304&stc=1&d=1392319185

[notorious]

With the roof panel shut, there are a total of 6 T25 torx screws to remove. 1/4" socket set gave plenty of access. I inverted the panel and undid the screws and lifted the frame off as I was working on my own and didn't fancy dropping it!


Are these screws specific to solar panel only?
Can I reuse the 6 screws that are currently used in my aluminium panel?

The reason why I'm asking is because I sourced only the solar sunroof, but not the complete tray.

[thebluewhale]

I've got as far as fitting the panel on mine. The panel is a like for like fit so you can reuse the screws.+++

[Adrian E]

In a car with solar sunroof there is a hole in the tray for a sunroof wire.
Can I expect to have the same hole in the tray of a car without solar sunroof?


Your pic doesn't show Sergey - are you talking about the hole to retain the connector, or the one where the electrical wiring passes through from the contact to the underside of the panel?

This is how the wiring runs through when you've removed the upper rail:

http://i5.photobucket.com/albums/y180/BX16VALVE/Audi%20S8/Solar%20sunroof%20retrofit/5E4B2325-0679-4A1F-9648-00C7F05CDF20-214-0000003E76454BE9.jpg (http://s5.photobucket.com/user/BX16VALVE/media/Audi%20S8/Solar%20sunroof%20retrofit/5E4B2325-0679-4A1F-9648-00C7F05CDF20-214-0000003E76454BE9.jpg.html)

[notorious]

The one where the electrical wiring passes through from the contact to the underside of the panel. Your picture is correct.

Shall I expect the same hole in a tray that was used in cars without sunroof?

(I appreciate I will need to disasseeble connector or the contact to run the wire through the hole).

[PsYcHe]

Pretty sure there's space to run it from memory when I did Jim's sunroof.

[Adrian E]

I believe so - with the panel back just undo the bolts holding the front section in and lift it up. You can do that no problem to have a look-see without disturbing anything else.

I'd say definitely taking the black plug contacts out is the way to route them through :) they come out easily

[texas2201]

Ian retro fitted one into my car years Ago - it was a dry but cold day :-)

mine is an early one a 1994

it sometimes sets off the alarm when the fans start extracting - Ian did send me something to fit to see if we could isolate this but it is still in an envelope somewhere

[yrk2.7t]

Can you easily replace just sunroof portion from a glass sunroof to a solar one?

Or is it just easier to replace the entire assy?

[The_Laird]

You need the glass and the 'runners' (and wiring and a relay), but not the whole assembly

[Adrian E]

If you have a glass sunroof with sliding inside cover you also need to remove that and replace with one designed to slide with the panel only

[pajacobs69]

Hi I have an Audi A8 4.2 V8 Quattro 1999 FL and I have just noticed that my Solar sunroof has shattered! Can anyone tell me how to remove damaged solar sunroof panel with a replacement one please?

[Architex_mA8tey]

Hi I have an Audi A8 4.2 V8 Quattro 1999 FL and I have just noticed that my Solar sunroof has shattered! Can anyone tell me how to remove damaged solar sunroof panel with a replacement one please?

Section 60 Page 110 of this should help -
http://forum.a8parts.co.uk/attachment.php?attachmentid=9870&d=1420350770

[tintin]

Hi I have an Audi A8 4.2 V8 Quattro 1999 FL and I have just noticed that my Solar sunroof has shattered! Can anyone tell me how to remove damaged solar sunroof panel with a replacement one please?

And this might help -

http://forum.a8parts.co.uk/showthread.php?t=5370&highlight=solar+sunroof+fitting

which is the thread that Ian (IT) did when he replaced my steel roof with a solar one a few years ago: this covers more that just replacing a shattered one, but probably has what you need. If it doesn't, then try using the search facility on here for "solar sunroof fitting", and that may give you what you need.