How to Troubleshoot & Replace Bosch AP2838563 / 00189324 Ignition Plug Assembly

Bought a Thermador PRSE48" dual fuel range from Craigslist really cheap because it didn't work. Did a little research and decided to overhaul most of the top (gas) end. For what I paid for it it was worth it and I'd have a good stove with new components. Replaced the griddle thermostat, ignition micro switches, ignition re-igniter box, installed fixing kit with 2 new potentiometers, both solenoids, and gas regulator. Had to replace 2 gas lines, all 4 jets, and one brass nut that were corroded or damaged in removal. Replaced all igniters and clips and main oven door seal. Kept the wiring harness. The only issue was the directions for re-igniter are WRONG. Don't connect wires to the same "number" as directions say, instead connect them in the same "position" as the old one. I connected them to the number as directions say for 4-burner but the ignition won't stop after lighting - it just keeps ticking away. Pulled it apart and put them to the same position (it says to do for a 6-burner) and then it worked correctly. Spent about 2 months cleaning it - it was filthy inside and out. Now it looks great and everything works perfectly. A like-new 48" Thermador for the cost of parts. 90% of the time spent was cleaning. I'm just a DIYer and have never owned a stove like this or overhauled a stove before and it wasn't a bad project. 

Removed old igniter, attached new one to old wire. Did not have to disassemble cooktop, just the one burner. Took ten minutes. The burner was held in place by a wide circular nut, too wide for a screwdriver, but a 2" fender washer fit the grooves and acted as a screwdriver, 

Took out igniter module and porcelain was cracked. Replaced with ordered part and it worker fine! 

On dissasembly the venturi was fused into the jet holder which caused the whole assembly to spin and ruined (spun) the burner supply tube in the process. Apparently not uncommon as the Appliance Parts Pros website popped up all of the parts I needed. Started as a junior nightmare and ended painlessly. 

Hardest part was proper diagnosis. The gas simmer controller and potentiometer's that support the extra-low simmer feature on the 2 left burners are apparently common culprits. I had to use a Volt meter to zero in on the bad solenoid. The second hardest part was getting at the burner compartment. See this helpful video: https://www.youtube.com/watch?v=g8_rUV0wFyM. The venturi tubes like to "weld" themselves to the jet holder. I tried solvent and a 20mm socket wrench. That worked on one, but not the other. No luck. Ultimately had to use a dremel tool to cut through one of the tubes at about one half inch below top to free the cover. Then, I removed more piece to get at the faulty solenoid. I replaced it, tested it, and put everything back together. It took awhile, but it works quite well now. 

Appliance Parts Pros sold me 2 ignitors, (one spare). They were the correct items and were received very quickly. The igniter just goes into a hole with a spade connector on the wire that pulled up enought to make th connection. 

I first used penetrating fluid and let it soak. The venturi was so frozen that the internal bracket that holds the jet holder spun out of the it's holders when I tried to loosen the venturi ( now I have problems). I then used a dremal type tool with a cutting disk to groove the top of the brass venturi, about 12 cuts. I then hammered out the tiny brass pieces with a screw driver. That allowed me to take the top off. Inside was a broken off gas burner tube and frozen venturi still in the jet holder. Ordered all new parts and replaced them. USE ANTI SEIZE WHEN SCREWING THE VENTURI INTO THE JET HOLDER. 

With the help of Appliance Parts Pros, I received the parts in a couple of days. The repair video was very helpful with the repair. The only delay was a wire came loose when I dropped the panel to replace the potentiometer. I called the tech and got a copy of wiring diagram and got it back together and it works fine. This is my 2nd experience with Appliance Parts Pros and both times I have been successful in repairing my 20 year old Thermador range. Would highly recommend your parts and tech department to all. 

Replaced the solenoid in the one with the low simmer feature and replaced the igniter in the other standard burner. 

Turn off the gas to the range top, disconnect the gas supply and unplug the power source. Removed the range top from the counter, then removed the burners by unscrewing the brass center/ Lifted the top-up carefully by tilting so I had access to the igniter. Removed the clip holding the igniter. Replaced the igniter and re-assembled the cooktop. Re-installed the cooktop and connected gas and power. Checked for gas leak then tested all burners. Worked perfectly. Total time about 1 hour. Parts arrived within 48 hours of placing the order. You guy are awesome!!