Manifold & Gas Valves Replacement - Flatrock 2-Zone

How to replace the manifold and gas valves on the Flatrock 2-Zone grill.

Applicable SKUs

• FTK0100

Replacement Steps

1. Move burner knobs to the OFF position.
2. Close the propane tank valve and disconnect the regulator from the propane tank.
3. Remove propane tank and set aside.
4. Remove the griddle knobs.
   
5. Fold down the righthand side shelf, exposing 2 bolts.
   
6. Remove the side shelf by removing the 2 bolts on the front bracket and the 2 bolts on the back bracket.
   •  Be sure to hold the shelf so it does not drop when removing the screws.
   • You may need the help of another person for this as the shelf can be awkward to remove.
7. Remove the regulator hose bracket located underneath the grill by removing the x2 screws.
   
8. Use a Phillips screwdriver to remove the two screws at the bottom of the control board. 
   
9. Slide the control panel to the right until it stops and pull the panel away from the wall of the grill body. 
   • This at times can be tricky. It helps to jiggle the control panel and lift upward to get it off the mounting screws. This may take some effort to get the panel to come off.
     
10. Remove the x6 screws on the front brackets (x3 screws per bracket).
    • Remove the x4 bottom screws first (2 on each bracket), followed by the x2 top screws (1 on each bracket).
      
11. Pull the valve bracket away from the grill.
    
    
    
12. Unhook the ignitor wire from the ignitor.
    • Repeat on other side. 
    • It may be helpful to use needle nose pilers for this
      
13. Remove the x1 screw from the gas hose plate.
    
14. Remove the plate.
15. Using a 5/8" and a 3/4" wrench, unscrew the regulator hose from the valve bracket.
    • Use the 5/8" wrench to hold the gold section in place, use the 3/4" wrench to loosen the silver nut.
      
16. Remove manifold and gas valves from the grill.
17. Reverse the steps to reinstall the new manifold & gas valves.
18. Feed the regulator hose from underneath the grill through the opening on the front righthand side and reconnect it to the new manifold & gas valve.
    1. Do not use thread sealant tape.
    2. Thread the female fitting of the regulator hose assembly onto the male fitting of the manifold, by hand.
    3. The female fitting on the regulator hose should rotate at least two full turns before there is any resistance. If there is any resistance before this point it is because the threads are not aligned correctly (cross threaded), the threads are damaged, or there is debris in the threads. If this is the case remove the hose, inspect the threads on both fittings, and try to install it again. Tighten the female fitting as much as possible by hand.
    4. Use the 5/8” wrench on the manifold fitting and the ¾” wrench on the hose fitting and tighten the connection.
       Be careful to not over-tighten. It should rotate about 1/16 to 1/8 of a turn past hand tight and then a little more force applied so it is snug.
       
       
19. Feed the tube through and replace the plate using the x1 screw.
    
20. Reattach both ignitor wires using needle nose pliers.
21. Slide the manifold & gas valve part onto the grill. 
    • Ensure the tubes are lined up with the openings.
      
22. Replace x6 screws on brackets.
    • Replace x2 top screws first, followed by x4 bottom screws.
      
23. Reattach the regulator hose bracket underneath the grill with the x2 screws.
    
    
    
24. Replace the control panel by placing it over the bolts and sliding to the left.
25. Replace the side shelf.
26. Replace burner knobs.
27. Replace the propane tank and reattach the regulator hose.
28. Check for gas leaks.
    1. Open propane tank valve but leave burner knobs in the OFF position.
    2. Spray the connection with soapy water and check for bubbles.
    3. If bubbles are present, tighten connection.