I just got back from the dealer after refusing the $400 or so charge to replace the TBB on my 02 s4. They made it sound like a pain in the *** but me working for a week to pay for auto repairs is a pain in the *** too. So I bought the stock TBB from the dealer for $14 and was wondering if anyone could provide me with instructions on how to replace it since they made it seem difficult. If there is somewhere online I could find this info please direct me to it. Also any tips when doing this or things I should be careful of would be very helpful as well. Thanks!

 

Any help? At least what do I need to take off in order to be able to replace it? Has anyone here replaced one of these themselves?

 

I think you have to take off the y pipe on top of the engine. There are 5 bolts. 3 on top and 1 near each turbo. You also need to remove the pipes leading to the tbb. There is one bolt holding those on on each side. Make sure you lift it up out of the grove in cam cover otherwise youll brake the grove in the cam cover. Not the end of the world as you dont need the groove, but you dont want to brake it. Youll probably have to remove the diverter valves also. Those should have screw clamps to remove.

 

ok. You are not out of your league replacing your own throttle body boot. Naturally Audi is going to make it sound ridiculously difficult. It isnt, as long as you are not a complete retard. Here is a link with the step by step process on how to replace it. Follow them exactly so that you dont damage anything, it is not worth it to try to cut corners. I would also recommend replacing your stock boot with a silicone one made by samco. The aftermarket boot is like $80 but you should not have to replace it ever again. If you do this, you will find that the O2 sensor does not fit into its port perfectly, and you have to flex the metal bracket so that it is secure. The samco boot is also shaped just a little bit differently, and because it is, your "biturbo" plastic engine plate will not fit back on correctly. just leave it off. If you are really that hellbent on keeping that lame plate in view, use the stock one, and you will get to replace it over and over again every so often. good luck.

 

It very easy to replace;

-Take the front engine cover off.
f-ollow the intercooler pipes (the hard plastic ones) down to where they bolt to the motor (10MM bolt) remove that bolt on each side to give you a little room to move them around
-Loosen both IC pipe clamps of the TBB
-Pull IC pipes out of the TBB
-You might have to take the two bolts out of the air intake sesor to get it out of the way
-loosen the TBB clamp on the throttle body
-Pull the boot out.

 

sorry, forgot the link

http://www.audiworld.com/tech/eng19.shtml

 

Just replaced mine with the Samco TTB from AWE, new clamps included. No more tears. I used a small shoe horn to guide the boost tubes into the TTB which made the process much easier. It shouldn't take more than 30 -40 minutes.

 

Thanks for all the help guys! The instructions in that link were dead on! Aside from taking a trip to the local auto store midway for a hose clamp the hole process took about 40 minutes. Of course I was pretty pissed when I found out my TBB wasnt even busted. Time for a pissed off phone call to the Audi dealer manager to ask them why they are ripping people off with $450 charges to replace a TBB that only takes 30 minutes and costs $15. Especially when its not neccessary!