How to Replace Your KitchenAid Gas Cooktop’s Burner Valve

Fred's Appliance
January 7, 2019
Oven Repair

If one of your burners isn’t lighting up, it might not be receiving any gas. That means you need to replace the attached burner valve. With a replacement burner valve and a bit of time, you can replace the broken part yourself. Just order replacement part #W10844473 for your KitchenAid gas cooktop and follow these steps. Depending on the valve that needs to be replaced, check with your appliance manual to ensure you get the correct part.

1. Unplug the cooktop and shut off the gas supply.

Whether you’re working with a gas appliance or a purely electrical one, the first disconnect it from the power source. Because you will be removing the control knobs and disconnecting gas supply lines during the course of this repair, make sure the power cord is unplugged and the gas supply is shut off. If your cooktop is wired directly into your house’s electricity, flip the appropriate circuit breaker. 

2. Disassemble the top of the cooktop.

Remove the screws holding the brackets on the underside of the countertop that secure the cooktop to the countertop. Loosen the adjustment screws in the middle of the brackets without removing them. Then rotate both brackets ninety degrees so they don’t cross underneath the cooktop. Retighten the screws to hold the brackets in place.

Loosen the clamp around the venting to disconnect it from the blower.

Remove the three grates and the vent grill from the top of the cooktops. Also, remove the burner caps and bases. After that, remove the six control knobs from the valve shafts and set them aside.

Pull the cooktop slightly above the countertop. Slide two pieces of wood between the cooktop and the counter to hold it elevated.

Then remove the four orifice holders. To do so, loosen the two screws holding each one in place. Locate the blower switch mounting bracket or the bottom right of the six valve shafts. This has the screw that secures the top panel to the countertop. Loosen and remove the screw. Now you can pick up the top panel and access the internal parts. Set the top aside.

3. Remove the burner valve manifold assembly.

First, loosen the nuts holding the gas supply lines to each of the five burner valves. Also, loosen the nut holding the main supply line to the manifold. Pull each of the supply lines away from the valves so they don’t catch on anything when you remove the manifold assembly later.

Next, unplug the wire harness connecting the manifold assembly to the cooktop.

Look on the casing just outside the manifold assembly. Loosen and remove the six screws that hold the manifold in place.

Remove the manifold carefully, and make sure it doesn’t tug on the wires or gas supply lines. Set it aside.

4. Remove the broken burner valve.

Locate the burner valve that needs to be replaced. Then pull off the white circular shield and the red spark switch beneath it. They should easily slide up off the burner valve. Next, flip the assembly over. Locate the screw holding the burner valve and its bracket in place. Then loosen the screw. Remove the bracket and the burner valve.

5. Install the new burner valve.

Line up the bottom of the new burner valve with the hold in the manifold. Hold it in position as you align the bracket in place on top of it. Then secure both parts in place with the screw. Be careful not to overtighten.

Flip the manifold assembly over. Slide the red spark switch over the valve and push until you hear a click as it locks into position. Also add the white shield.

6. Reassemble the manifold assembly.

Pick up the whole assembly and position it back inside of the cooktop. The front left corner will fit under the metal bracket in the corner of the cooktop. Hold the manifold assembly in place and retighten each of the six screws that hold the assembly in place against the casing. Once it’s in position, reconnect the main wire harness. Then connect each of the five gas supply lines to the valves and tighten the nuts. Make sure you connect and tighten the main gas supply line into the manifold assembly, too.

7. Reassemble the cooktop.

Pick up the top cooktop panel and align it with the cooktop. Make sure the surface igniters align with the holes so the top with flush with the edges of the cooktop. Carefully wiggle the igniters to make sure they fully protrude through the holes in the top. Then tighten each of the two screws that secure the top in place. Repeat for each of the three remaining orifice holders. Make sure the screws aren’t overly tightened.

Next, tighten the screw holding the top to the mounting bracket for the blower switch. Add the control knobs back onto each burner valve. Align the knobs based on the shape and orientation of the shaft and press them down into position.

After that, reattach the burner bases. Match each base with the correctly sized orifice holder. Each spark igniter should fit into the groove on each of the bases. Then add the burner caps to each of the burner bases.

Lay each of the grates and the grill into place on the cooktop.

Now that the top is fully secure and reassembled, lift up the cooktop. Remove the two pieces of wood and lower the whole cooktop back into the cutout portion of your countertop.

Go underneath the countertop. Loosen the middle adjustment screws for each bracket, but don’t remove the screws. Then rotate the brackets ninety degrees so they are perpendicular to the line between the cooktop and the countertop. Do this with each of the support brackets. Add the screws back in place on the outer edges of the brackets to more securely hold the cooktop in place.

After that, reconnect the venting to the to the blower. Tighten the clamp to lock it in place.

Turn on the gas supply and plug the cooktop in. Test the flame output from the new burner valve to make sure it has an appropriate flame height for low and high settings.

If you have more appliance repairs you want to make, go to Fred’s Appliance Service for more repair tips. You can also schedule an appointment with a trained appliance repair technician who can troubleshoot your appliances and make quick repairs.

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