Thermador Professional Series User manual

SERVICE MANUAL
Thermador
Professional Series
Rangetop
Model: PCG366G/03
This manual contains information that is necessary for
servicing the following Thermador Professional Series
Rangetop:
PCG366G
Due to the complexity and the risk of high-voltage
electrical shock, customers should not service their
appliances.
The information provided in this document is intended for
trained, qualified personnel only. The proper function and
the safety of the appliance can be affected by an
improper repair, and even serious threats to life or
physical condition may arise. BSH Home Appliances
Corporation is not liable for damages caused by improper
repairs performed by unauthorized parties. Local codes
and standards apply and must be observed. Contact
Technical Support for further assistance.

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TABLE OF CONTENTS
1General........................................................................................3
1.1 Included with the Product......................................................3
1.2 Optional Accessories (Not Included).....................................3
1.3 Data Plate..............................................................................3
1.4 Recommended Tools and Supplies ......................................4
1.5 Important Safety Information.................................................4
1.5.1 Safety Symbols Used In This Manual............................4
1.5.2 Safety Precautions to Know Prior to Servicing...............4
2Operation.....................................................................................7
2.1 Control Knobs........................................................................7
2.1.1 ExtraLow Feature...........................................................7
2.2 Automatic Re-ignition............................................................7
2.3 Operation during a Power Outage.........................................8
2.4 Main Components and Locations..........................................8
2.4.1 Burner Assembly and Maintop.......................................8
2.4.2 Components under the Maintop.....................................9
3Testing Burners and Ignition.....................................................9
3.1 Before Testing.......................................................................9
3.2 Burner Characteristics.........................................................10
3.3 Flame Characteristics..........................................................10
3.4 Testing Burner Ignition........................................................11
3.5 Testing the HI Setting..........................................................11
3.6 Testing the SIM Setting.......................................................11
3.7 Testing the XLO Setting......................................................11
3.8 Manually Setting Burner Valves - Natural Gas Units...........11
3.8.1 Tools Needed...............................................................11
3.8.2 Adjusting the Bypass Screws.......................................11
3.9 Burner, Flame, and Ignition Troubleshooting......................12
3.9.1 Burner and Flame Diagnostics.....................................12
3.9.2 Ignition Diagnostics......................................................12
4Service and Repair...................................................................14
4.1 Preparing the Rangetop for Servicing.................................14
4.1.1 Removing Knobs, Grates and Burner Assemblies ...... 14
4.1.2 Removing the Maintop................................................. 16
4.1.3 Removing the Heat Shield........................................... 16
4.2 Component Removal and Replacement............................. 17
4.2.1 Jet Holder Assembly and Burner Support Rail Removal
and Replacement....................................................................... 17
4.2.2 Jet Holder Assembly Removal and Replacement ....... 19
4.2.3 Manifold Removal and Replacement........................... 20
4.2.4 Standard Valve Removal and Replacement................ 22
4.2.5 Microswitch Removal and Replacement...................... 23
4.2.6 Solenoid Valve Removal and Replacement ................ 24
4.2.7 XLO Valve Removal and Replacement....................... 25
4.2.8 Potentiometer Removal and Replacement.................. 27
4.2.9 Control Panel Removal and Replacement................... 28
4.2.10 Regulator Removal and Replacement......................... 30
4.2.11 Ignition Device Removal and Replacement................. 31
4.2.12 LED Indicator Removal and Replacement................... 31
4.2.13 Simmer Control Board Removal and Replacement..... 32
5Before Returning Appliance To Service ................................ 33
6Clean-Up ................................................................................... 33
7Technical Specification........................................................... 33
8Additional References............................................................. 34
8.1 QuickFinder ........................................................................ 34
8.2 Technical Support............................................................... 34

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1 GENERAL
The 36-inch Professional Series Rangetop features the pedestal
Star® burner that offers the fastest time to boil, the Quick Clean
Base™, cast-iron grates, an easy-to-clean porcelain maintop, and two
ExtraLow® simmer burners that enable a wide range of simmer
capabilities. The 36-inch Professional Series Rangetop is compatible
for use with natural gas, or liquid propane gas using the LP Gas
Conversion Kit – refer to QuickFinder for the most current revision of
PALPKITHC (649832).
1.1 Included with the Product
The following are included with the appliance:
Use and Care manual
Installation instructions
Product registration card
Star burner caps
Cast iron burner grates
Metal control knobs
Island trim
1.2 Optional Accessories (Not Included)
12-inch Low Back Guard 36-inch PA36GLBC
LP Gas Conversion Kit PALPKITHC (649832)
12-Inch Grill Accessory with Dip-Tray PA12GRILHC
12-Inch Grill/Griddle Cover PA12GCVRHC
Griddle PAGRIDDLE
Blue Metal Knob Kit PAKNOBLU
Black Metal Knob Kit PAKNOBLK
Wok Ring PWOKRINGHC
12-Inch Maple Chopping Block PA12CHPBLK
24-Inch Maple Chopping Block PA24CHPBLK
1.3 Data Plate
The data rating plate showing the model, serial, and FD numbers is
located on the underside of the rangetop chassis near the gas inlet
connection and electric power cord, as shown in Figure 1. This
information is required if customer service is requested.
Figure 1: Data Plate
The first 4 positions of the FD number reflect the year/month the
product was produced. For example, FD numbers that begin with 87
were built in 2007; numbers that begin with 88 were built in 2008, etc.

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1.4 Recommended Tools and Supplies
The following tools and supplies are recommended to use when
servicing this appliance:
Driver sizes: T-10, T-20, T-25, T-30
¼ inch nut driver or ¼ inch socket wrench / ratchet
Wrench sizes: ½ inch, 5/16 inch, 11/32 inch open end
Socket wrench / ratchet 11/32 inch
Adjustable wrench
Pipe wrench
Precision screwdriver with high-strength blade, 1/8" [3.0mm] wide,
.020" [0.50mm] thickness tip
Flat blade screwdrivers: large, small
Swivel head driver with a 11/32 inch, deep well socket
Slip joint pliers
Small needle nose pliers
Hook or non-straight hex key (Allen wrench)
Protective gloves
Gas leak test equipment
Pipe sealant
1.5 Important Safety Information
Before starting to service an appliance, familiarize yourself with all
safety information and precautions contained in this manual.
1.5.1 Safety Symbols Used In This Manual
This symbol alerts you to dangers that may result in bodily injury or
death.
Caution
This symbol alerts you to actions that may result in damage to the
product, or property.
1.5.2 Safety Precautions to Know Prior to Servicing
Before You Start Servicing the Appliance
Before disassembly, removal or installation of any component, do the
following:
■Turn off electrical power by removing the power cord from the
electrical outlet, and putting the circuit breaker in the OFF position
(or removing the fuse)
■Turn off the gas supply to the appliance
■Make sure grates and burner assemblies are cool before
removing them

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Replacement Parts
Use only authorized replacement parts per catalog for this appliance.
Use of substitutions may defeat compliance with safety standards set
for home appliances, will void the warranty, and may create safety
hazards resulting in bodily injury, death, or damage.
Fire / Explosion Hazards
■Make sure the gas valve at the wall is closed before removing and
installing any gas components.
■Do not store or use any flammable vapors, liquids, or combustible
materials in the vicinity of this appliance.
■Do not use water on grease fires. Turn appliance off and smother
the fire with baking soda or use a dry chemical or foam-type
extinguisher.
What to Do If You Smell Gas
■Do not try to light any appliance
■Do not touch any electrical switch
■Do not use any phone or cell phone in the building
Installation and service must be performed by a qualified installer,
service agency, or the gas supplier.
Testing for Gas Leaks
■Do not ever use a flame to test for gas leaks, as doing so may
result in explosion, injury, death, and/or damage to the appliance
and property.
■With electrical power off, carefully check for gas leaks at each gas
component that was removed, replaced, or otherwise serviced
using a gas leak detector or bubble test.
Electrical Hazards
■Before servicing the appliance, remove electrical power by either
disconnecting the power cord from the wall receptacle, or by
shutting off the circuit breaker.
■If tests have to be conducted while the appliance is live, always
use a residual-current-operated circuit-breaker. The protective
conductor connection must not exceed the recommended values.
■When repairs are complete, perform a function test in accordance
with the appropriate regulations.
■Do not under any circumstances cut or remove the separate
ground wire or the third (ground) prong from the power cord plug.
■Improper grounding or reverse polarization will cause malfunction
(such as continuous sparking of the igniters), which can damage
the appliance and create an electrical shock hazard. Make sure
the circuit is properly grounded and polarized in accordance with
applicable local codes and ordinances. Receptacle replacement
shall be in accordance with the National Electric Code.

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In Case of Power Outage
1. If for any reason a control knob is on when there is any failure or
removal of electrical power from the appliance (such as a power
outage), immediately turn all control knob(s) to the OFF position.
2. Ventilate by opening a door or window, and wait at least 5minutes
for all the gas to dissipate.
3. If you smell gas, refer to the applicable safety precautions stated
in this manual.
Sharp Components
This appliance has sheet metal and other components which often
have sharp edges. When working on this appliance, avoid cutting
yourself and other injury by handling these parts with care and using
adequate protective measures, such as gloves.
Clean-up Hazards
Don’t allow any cleaning or polishing solutions/compounds,
disinfectants or bleaches to remain in contact with the stainless steel
surfaces for long periods, or after clean-up. These may contain
chemicals or materials which could release harmful inhalants and can
damage the appliance. After cleaning or polishing, always rinse the
cleaning/polishing materials with clear water and wipe dry with a clean
soft, non-abrasive cloth.
Prior to Returning Appliance to Service
Prior to returning the appliance to service, make sure that:
■All electrical connections are correct and secure
■All safety grounds (internal and external) are correctly and
securely connected
■All gas connections are secure and have been leak tested using a
gas leak detector or bubble test.
■All panels and components are properly and securely
reassembled
Caution
Code Compliance
Local codes vary. Installation, electrical connections, gas connections,
and grounding must comply with all applicable codes.
TESTED IN ACCORDANCE WITH ANSI
Z21.1, THE STANDARD FOR HOUSEHOLD
COOKING GAS APPLIANCES. IN CANADA
TESTED IN ACCORDANCE WITH
CAN/CGA1.1 – M81, THE STANDARD FOR
DOMESTIC GAS RANGES.
Check your local building codes for the proper
method of installation. In the absence of local
codes, this unit should be installed in accordance
with the National Fuel Gas Code No. Z223.1/
NFPA 54 current issue and the National
Electrical Code ANSI/NFPA No. 70 current issue
or the Can – B149 Installation Codes for Gas
Burning Appliances and C22.1 Canadian
Electrical Code Part 1.
It is the responsibility of the owner and the
installer to determine if additional requirements
apply in specific installations.

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2 OPERATION
2.1 Control Knobs
The control knobs for each of the burners are located on the control
panel, with an icon above to identify the location on the rangetop (see
Figure 2). The left-front and left-rear burners have the ExtraLow (XLO)
feature.
Figure 2: Burner Control Knobs
1. Press a control knob in, and turn counter-clockwise to HI setting.
The igniter for the burner clicks while sparking until flame ignition.
Burner should ignite within 4 seconds.
2. For the two right burners and two middle burners, rotate the knob
to any setting between HI and SIM. For the two left burners, rotate
the knob to any setting between HI and XLO.
NOTE: The blue LED indicator will light up when the burner(s) are
lit.
2.1.1 ExtraLow Feature
When the knob is set to XLO - the very lowest setting, the flame
cycles on for approximately 8 seconds and then turns off for 52
seconds of each minute.
The knob can also be set between SIM and XLO for a variable range
of low heat, with the flame cycling on and off at a different frequency
than the XLO setting (see Figure 3).
Figure 3: XLO Setting Range
2.2 Automatic Re-ignition
Each burner has its own electronic igniter that sparks when the burner
is turned on. If one or more burner blows out, the respective
igniter/electrode automatically re-ignites the flame.

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2.3 Operation during a Power Outage
When there is a removal of electrical power, the XLO burners cannot
be used. Do not attempt to light them manually.
Caution
Power Outage Precautions
■Ventilate well by opening a door or window, and wait at least five
minutes until all the gas dissipates.
■If you smell gas, comply with the warnings and precautions in the
Important Safety Information section of this manual.
2.4 Main Components and Locations
2.4.1 Burner Assembly and Maintop
Figure 4: Burner Assembly and Maintop

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2.4.2 Components under the Maintop
Figure 5: Components under the Maintop
3 TESTING BURNERS AND IGNITION
Servicing Burners and Ignition
Burner and ignition servicing must be performed by a qualified
technician. Improper adjustments may be dangerous, cause damage
or harmful by-products, and may void the appliance warranty.
Ignition Hazard
Do not touch burners when the igniters are active (sparking).
3.1 Before Testing
Before testing the burners and ignition, do the following:
1. Re-install any loose components that may have been removed
earlier, such as burner caps and grates. Be certain that burner
caps seat properly into the burner bases, and that the ignition
wires are properly positioned.
2. To test for gas leaks, make sure the electrical power is removed
and the manual gas shut-off valve is open, and then carefully
check rangetop components and gas supply for leaks using a gas
leak detector or bubble test.
3. After gas checks are complete and before testing, connect the
rangetop to the electrical power supply.

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3.2 Burner Characteristics
If one or more burner blows out, the respective igniter electrode
automatically re-ignites the flame.
At each burner port the flame should burn completely around the
burner cap.
It is normal to hear the following during burner operation:
•A slight sound that is associated with gas combustion and ignition
•A clicking noise every time the gas cycles, coming from the
solenoid valves of the two left burners
•When using LP gas, a slight “pop” sound may be heard at the
burner ports a few seconds after the burner has been turned off.
NOTE: If burner characteristics are not adequate, see Burner, Flame,
and Ignition Troubleshooting, page 12.
3.3 Flame Characteristics
Natural gas: The burner flame color should be blue with no yellow on
the tips (see Figure 6). It is not uncommon to see orange in the flame
color; this indicates the burning of airborne impurities in the gas, and
will disappear with use.
LP gas: Slight yellow tips on the primary flame cone are normal and
may appear after a few minutes. The flame should be stable with no
excessive noise or fluttering. Orange colored streaks in the flame are
produced from burning airborne debris, which is normal at startup,
and should dissipate in a few minutes (see Figure 7).
When the flame for both natural gas and LP gas is properly adjusted,
it should burn at each burner port (completely around the burner cap).
NOTE: If burner characteristics are not adequate, see Burner, Flame,
and Ignition Troubleshooting, page 12.
Figure 6: Correct Flame Characteristics for Natural Gas
Figure 7: Additional Flame Characteristics

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3.4 Testing Burner Ignition
Ignition Hazard
Do not touch the burners when the igniters are sparking.
■Push burner control knob in, and turn counter-clockwise to HI.
The igniter should produce a clicking sound as it is sparking, and
the burner should light within four seconds.
3.5 Testing the HI Setting
Set the burner knob to HI, and observe flame characteristics
(see Figure 6 and Figure 7). If any rangetop burner flame burns
primarily yellow, verify if the burner cap is positioned properly on the
burner base, and then re-test. If flame characteristics do not improve,
call Thermador technical support at [phone].
3.6 Testing the SIM Setting
Set the burner knob to SIM. Make sure that the flame completely
surrounds the burner. There should be a flame at each burner port
and there should not be an air gap between the flame and the burner.
If the flame does not extend completely around any of the burners,
call Thermador technical support at [phone].
3.7 Testing the XLO Setting
The left-front and left-back burners have the XLO feature. Set the
burner knob to XLO and observe if the flame cycles correctly - on for
approximately 8 seconds, and then off for 52 seconds of each minute.
3.8 Manually Setting Burner Valves - Natural Gas Units
When using natural gas, although pre-adjusted, if you need to set the
XLO valves and standard valves for the lowest possible flame setting,
then manually adjust the bypass screws on all valves.
For manually setting the valves when using LP gas, refer to
QuickFinder for the LP Gas Conversion Instructions PALPKITHC
(649832).
3.8.1 Tools Needed
■T-20 driver
■A precision screwdriver with high-strength blade, with 1/8"
[3.0mm] wide, .020" [0.50mm] thickness tip should be used to
reposition the bypass screws for minimum flow settings on manual
valves.
3.8.2 Adjusting the Bypass Screws
1. Remove knobs from valve stems by slowly pulling knobs straight
out, away from control panel.
2. Remove and retain the bezel mounting screw located to the right
of the valve stem, using a T-20 driver (see Figure 8).
3. To engage the valve screw, insert the precision screwdriver with
1/8” blade into the same hole in the bezel that was created by the
removal of the mounting screw (see Figure 9).
4. Turn the valve screw clockwise just until "bottom out" position is
reached. DO NOT over-tighten the valve screw (see Figure 9).
NOTE: The two valves for XLO operation (farthest left on control
panel) must be in the OFF position for proper access to the valve
screws through clearance holes in the XLO potentiometers.

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Gas Leaks
Carefully check for gas leaks at each gas component that was
removed, replaced, or otherwise serviced using a gas leak detector or
bubble test.
Figure 8: Removing the Bezel Mounting Screw
Figure 9: Accessing and Setting the Bypass Screw
3.9 Burner, Flame, and Ignition Troubleshooting
3.9.1 Burner and Flame Diagnostics
If a burner clicks (sparks) constantly, or if burner doesn’t light correctly
and/or has inadequate burner/flame characteristics (per Burner
Characteristics on page 10 and Flame Characteristics on page 10),
then do the following:
Check if the manual shut-off valve is open and the unit is receiving
gas (natural gas or liquid propane).
Check if the burner cap is properly aligned on the burner base.
Check if the burner port is open and not clogged or blocked.
Check if the igniter electrode is free from debris and is sparking.
If it is suspect that air is in the gas supply lines and system, you
can purge the remaining air by operating one of the burners for
several minutes.
Check if a fuse has blown or a circuit breaker has tripped.
For constant sparking, check wiring connections at ignition device
and electrode, and also check grounding
Refer to the Ignition Diagnostics, page 12.
Call Thermador technical support at [phone] for assistance if
any burners fail to light, or any of the burners continue to burn yellow.
3.9.2 Ignition Diagnostics
The following flowchart applies in the event a burner fails to ignite.
Before performing the steps in the Ignition Diagnostics Flowchart
(Figure 10), remove electrical power from appliance during
disassembly and during removal and installation procedures. Restore
electrical power when testing the unit if it is re-assembled.

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Figure 10: Ignition Diagnostics Flowchart

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4 SERVICE AND REPAIR
4.1 Preparing the Rangetop for Servicing
For most servicing of this appliance (for example, involving
disassembly, removal or installation), you will need to do the following
prior to starting:
■Turn off the gas supply to the rangetop by closing the gas valve at
the wall.
■Turn off the electrical power to the rangetop by removing the
power cord from the electrical outlet, and putting the circuit
breaker in the OFF position (or removing the fuse).
If testing the appliance requires the use of electrical power and/or an
open gas supply, exercise extreme caution.
4.1.1 Removing Knobs, Grates and Burner Assemblies
To access and service rangetop components located underneath the
maintop (see Figure 4 and Figure 5), remove the knobs, grates,
burner assemblies, maintop, and heat shield:
1. [Optional – only if a component attached to a knob needs
replacing] Remove knobs from valve stems by slowly pulling
knobs straight out, away from control panel.
2. Remove the three grates.
3. Remove all Star burner caps.
4. Remove and retain the two T-30 screws from each brass Star
burner base (see Figure 11).
Figure 11: Star Burner Base (Generation 5 Design Shown)
Caution
Fragile Component
The electrode is a ceramic component that can be brittle and crack
easily.

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5. While lifting the brass burner base, carefully press the locking tab
on the female terminal of the igniter wire, and gently pull to detach
from the electrode (see Figure 12 and Figure 13).
Figure 12: Igniter Wire Attached to Electrode
Figure 13: Igniter Wire Locking Tab
6. If the electrode needs replacing, remove and retain the small T-10
screw to detach it from the brass burner base. If not, leave it
attached to the brass burner base.
7. Remove and retain the T-30 screw holding the cast iron pedestal
burner to the maintop.
8. Remove the pedestal burner with the Venturi tube still attached to
it, while gently pulling the ignition wire through (see Figure 14).
-OR-
Alternatively, you can first lift the Venturi tube out from the
pedestal burner, before removing the pedestal burner from the
maintop.
Figure 14: Pedestal Burner with Venturi Tube
Press tab
to detach
from
electrode

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4.1.2 Removing the Maintop
Caution
Fragile Component
The porcelain enamel maintop is fragile. To prevent damage such as
chipping:
■Carefully remove the maintop
■Do not over torque the screw holding the burner pedestal to the
maintop when re-installing the maintop.
1. First, remove and retain the two T-20 screws from the inner,
frontward-facing left and right side corners of the rangetop chassis
(see Figure 15).
Figure 15: Screws on Inner Side of Chassis
2. Carefully place a tool such as a hook or non-straight Allen wrench
in a circular receptacle on the maintop (not in a receptacle for the
jet holder or the ignition wire), and pry up the maintop enough until
you can grasp it with your hand (see Figure 16).
3. Push each ignition wire downward through its respective
receptacle, as you carefully lift out the maintop, in a frontward
direction.
Figure 16: Removing the Maintop
4.1.3 Removing the Heat Shield
Sharp Components – Gloves Recommended
■Sheet metal components such as the heat shield have sharp
edges. Avoid injury by handling with care.
■It is recommended to use gloves when removing or installing the
heat shield.

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1. Carefully lift and remove the two heat shields (see Figure 17).
Figure 17: Removing the Heat Shield
4.2 Component Removal and Replacement
4.2.1 Jet Holder Assembly and Burner Support Rail Removal
and Replacement
This procedure is for the removal of the burner support rail with the jet
holder assemblies attached, which may be necessary in order to gain
access to components for servicing. If a jet holder assembly needs to
be removed from the burner support rail or needs to be replaced, see
Jet Holder Assembly Removal and Replacement, page 19.
Figure 18: Burner Support Rail
1. Follow all safety precautions and steps in the Preparing the
Rangetop for Servicing, page 14.
2. Using a 9/16 inch wrench, unscrew the hex nuts to remove the
gas tubes from the jet holder assemblies. Be careful not to bend
the gas tubes (see Figure 19).
Figure 19: Removing Gas Tube from Jet Holder Assembly
3. Using a 9/16 inch wrench, unscrew the hex nut to remove the
other end of the gas tubes from their respective valve as follows:
■[Left-side XLO valves]: While using a ½ inch wrench to hold
the bolt on the solenoid valve, unscrew the gas tube hex nut
with a 9/16th wrench. Be careful not to bend the gas tube (see
Figure 31).
■[Right side and middle standard valves]: Using a 9/16 inch
wrench, remove the gas tubes from the standard valves. Be
careful not to bend the gas tube.

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4. Push each ignition wire downward through its respective
receptacles in the burner support rail.
5. Make note of burner support rail placement on the rangetop
chassis (before removing the rails) so you can re-install afterwards
in the correct position.
NOTE: It is important to reinstall the correct burner support rails in
the correct position in order to correctly match up the jet holder
assemblies to the gas tubes.
Sharp Components – Gloves Recommended
■The burner support rail may have sharp edges. Avoid injury by
handling with care.
■It is recommended to use gloves when removing or installing the
burner support rail.
6. Using a large flat-blade screwdriver, push one side of the burner
support rail to the other side of the chassis, until the 2 prongs
come out from their slots on the chassis (see Figure 20). Then
remove burner support rail with the two jet holder assemblies
attached (see Figure 21).
Gas Leaks
Carefully check for gas leaks at each gas component that was
removed, replaced, or otherwise serviced using a gas leak detector or
bubble test.
Figure 20: Removing Burner Support Rail from Rangetop Chassis
Figure 21: Burner Support Rail with Jet Holder Assemblies Attached

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4.2.2 Jet Holder Assembly Removal and Replacement
This procedure is for removing the jet holder assembly from the
burner support rail, in the event that a jet holder assembly needs
replacing.
Sharp Components – Gloves Recommended
■The burner support rail may have sharp edges. Avoid injury by
handling with care.
■It is recommended to use gloves when removing or installing the
burner support rail.
1. Follow all safety precautions and steps in the Preparing the
Rangetop for Servicing, page 14.
2. Follow all steps in Jet Holder Assembly and Burner Support Rail
Removal and Replacement, page 17.
3. Remove the wire guard clip from each jet holder assembly prior to
removing the jet holder assembly from the burner support rail (see
Figure 22).
NOTE: The jet holders are secured to the burner support rails with
a tight fit.
4. As necessary, use a flat-bladed screwdriver to pry the jet holder
assembly out until the alignment boss is disengaged from the
circular receptacle on the burner support rail. Then rotate the jet
holder assembly (gloves recommended) until it can be removed
through the corresponding grooves in the burner support rail
(see Figure 22 and Figure 23).
-OR-
Alternatively, use a slip joint pliers and gloves to disengage the
alignment boss and rotate the jet holder assembly until it can be
removed (see Figure 22 and Figure 23).
Figure 22: Jet Holder Assembly – Detaching Alignment Boss from Rail
Figure 23: Jet Holder Assembly – Rotating and Removal from Rail
Alignment boss
Wire guard clip

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5. Replace the jet holder assembly if needed.
NOTE: If replacing the jet holder assembly, first install the jet
holder assembly onto the burner support rail before attaching the
wire guard clip.
Gas Leaks
Carefully check for gas leaks at each gas component that was
removed, replaced, or otherwise serviced using a gas leak detector or
bubble test.
4.2.3 Manifold Removal and Replacement
Although rangetop components can be accessed and replaced
without removing the manifold, this procedure is provided if the
manifold needs to be replaced due to a gas leak in the manifold, or if
the threading on the manifold is bad due to removing the regulator.
1. Follow all safety precautions and steps in the Preparing the
Rangetop for Servicing, page 14.
2. Remove the two knobs connected to the manifold support
brackets on the back of the control panel (see Figure 24).
3. Remove all gas tubes connecting the valves (both standard valves
and solenoid valves) to their respective jet holder assemblies.
Figure 24: Two Knobs Connected to Manifold Support Brackets
4. Remove the burner support rail (with jet holder assemblies
attached) by following the steps in the Jet Holder Assembly and
Burner Support Rail Removal and Replacement, page 17.
5. Remove the regulator from the manifold (see Regulator Removal
and Replacement, page 30).
6. Remove the microswitch and standard valve attached to the
right-most knob (see Figure 24). See Microswitch Removal and
Replacement on page 23,and Standard Valve Removal and
Replacement on page 22.
7. Remove the solenoid valve, XLO valve and potentiometer
attached to the left-side knob depicted in Figure 24. See Solenoid
Valve Removal and Replacement on page 24, XLO Valve
Removal and Replacement on page 25,and Potentiometer
Removal and Replacement on page 27.