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Whirlpool Refrigerator Repair – How to Replace the Nozzle and Tube Kit (Whirlpool # WP4388152)

” we’d like to explain you how to change the water line for the dispenser on your refrigerator. It’s a really easy job. Let me explain you how we do it.

There are a couple of methods that you can do this repair. One, you can choose to do it with the door still in place on the refrigerator.

That involves removing the lower hinge to give better access to the opening in the bottom of the door. You will have to prop that door up to support it. It’s probably just as easy to remove the top hinge.

Disconnect the harness there and lift the complete door off and do the repair on a flat work surface. Before we begin any of that, first thing we’re going to do is to disconnect power to the refrigerator.

Either put far enough forward that you can unplug it or locate the electrical panel, turn off the appropriate breaker, or remove the appropriate fuse. Once we’ve done that, and if you’ve chosen to remove the door and do the repair, you may wish to remove the items from the freezer and store them in a deep freeze temporarily. It’ll probably take 20 minutes or so to do the repair.

We’ve opened up both doors now and we’re going to remove this lower kick plate.

Just grasp the top of that on either side. Pull it forward. That will release these little arrowhead fasteners, and they attach into two springs on either side. We’ll set that kick plate aside.

NextWe’re going to lift up this water line.

We’ll disconnect the union from the outlet side to the door. There maybe a little water in that line, so you may want to have something there to wipe that up. I’m going to pull that knot off the bottom of that water line.

If you find that it won’t come off easily, just push it up onto the water line a ways, then snip off the bottom of the water line to get rid of that little bump, and then you can pull that right off. Now that water line will easily go through up that hinge in the lower door closer cam, without any problem, once you remove that. Now, our next step will be to attach a cord to this existing waterline.

Due to the design of the door, it’s not easy to push a new water line through it.

You’ll need to actually push on it and pull at the same time. We’re going to attach a very stout cord. We have a small gauge nylon cord that we’re going to use because there’s not a lot of extra room so you don’t want to use heavy cord on it, but it needs to be very strong.

ll easily fit up through

We found some very strong nylon cord, but it is a small diameter.

We’re actually going to tape that to the side of this waterline so we can keep the diameter as small as possible. We suggest that you don’t use a standard cotton type of cord. You actually use something very strong like a heavier fishing line, something like that, that will withstand some tension.

Then make sure it is secure to that water line, so that it doesn’t come loose.

hinge and

Again, we’ll keep the diameter overall as small as possible. Regardless of whether you remove the lower hinge and do the repair with the door in place, or whether you take the door off, which is the method that we suggest, you’ll need to firmly attach that line on there first. Just give it a good tug, make sure it’s nice and secure. Then our next step will be to go over the top of the door.

We’ll remove the hinge cover and remove the bolts that secure the upper hinge to the cabinet.

On this hinge cover, there is a single Philips screw at the very back. We’ll simply remove that. Slide that hinge cover forward and lift it off.

Now with the hinge cover removed, we next need to release the wire harness to the door and there’s a locking tab on both sides of the connector we’ll need to release. Take a flat blade screwdriver, I’m just going to the center of that, and just pry that up enough to make it loose. Do the same on the opposite side.

Then separate the two halves. Next, we’ll also need to remove the ground wire that is attached to the top of the hinge that uses a quarter-inch hex head screw.

We’ll just remove that single screw. Now with the harness completely disconnected, our next step will be to remove the three screws that secure the hinge to the cabinet. Typically, they will be a 5/16 hex head screw.

We’ll just loosen all of them with a ratchet or a wrench. Once we’ve loosened those, we then use a nut driver to remove them. Now with those three bolts removed, you then pivot that hinge, hold on to the top of the door, and then we’ll prepare to lift that door off and put it on a flat work surface.

Now we’re ready to lift that door off, the waterline will pull easily up through that lower hinge, so we won’t have to worry about that. We’ll just grasp the door securely, lift it off, then we’ll set it on a flat surface, and then we can go ahead and disconnect the waterline at the top here. Now with the door on a nice flat work surface, we’ll next identify which of the two styles of water lines that we’re going to use, by looking in where the actuator paddle is.

You can determine at that point whether it is the type that has a preformed plastic end on it, or whether it has the metal bracket. In either case, that will be attached to that lever with a quarter-inch hex head screw, so we’ll next remove that. We won’t pull this waterline out yet because due to the construction of this door, the openings are fairly small and you’re not easily able to push a new water line down through there.

You will also need to be able to pull on as well. What we’ll do is we’ll attach a small gauge nylon cord to the opposite end of this water line. Pull that water line up through with that cord, and then we can attach that to the new water line, which will allow us to be able to pull it, as well as push it down through that opening.

that opening

Our next step, we’ll go to the bottom of the door and we’ll prepare that tubing. The method that we’ve chosen is to take a nylon cord attach it to the bottom of this water line. We’ll just tape that in place.

We’ve doubled it up to give ourselves a little more strength and then we’ll tape it securely to the bottom of that water line and then pull it up through that door. You’ll find that the opening through the bottom of that door cam closer is a little snug, so we’re going to take that off first before we attach our line. You may also have to loosen this doorstop as well.

All 5/16 hex head screws involved here. Using a ratchet, we’ll just loosen two screws on the doorstop. You may or may not be able to get a socket on that screw on the door cam.

Take one of the screws out of the doorstop. Just pivot that up out of the way. We’ll loosen the screw for that cam and completely remove it.

You may need a putty knife to help pry that door cam loose.

Then just pull that completely out of the bottom of the door. That will give us much more room to pull that tubing and our cord through that opening. Now another method that you may choose to use to attach a line to that cord is, somebody will have taken a number 12 screw and threaded it part way up into that tubing, cut the head off of the screw, and then attach their line to the screw.

You’ll probably find that if you could get a nice nylon cord that’s plenty strong, that you can actually just tape it to the side of that line and it’ll still be a small enough diameter that’ll easily fit up through that opening. Keep that as small a diameter as you can and just give that a good tug and make sure that it’s on there nice and secure and then what we’ll do is we’ll carefully push it in from the bottom, while at the same time, we’ll pull on the top portion of that tubing until we have that all the way up through there.

Now as you pull the last of that through, you may need to push it up into that cavity enough to make sure that we’re going to get it all the way through. Just make sure that we secure the other end of that cord so that we don’t inadvertently pull it up into that opening. Next, we’ll remove that tape that we used to secure the line to that cord.

You can then discard the old water line. Now we’re ready to attach that nylon cord to the new tubing. AgainWe’re going to keep this tight as possible, to make sure that the diameter is as small as possible.

Again, do a good tug on that, make sure it’s nice and secure. NowWe’re going to have to form a little bit of a bend in the top of that until we start to feed it into that opening behind this lever. Make sure that we have good grip on the bottom side of that cord and then just tuck that in, so that it lines up, facing downward, into that opening in the dispenser area.

You may need to feed that a little bit by hand, as you’re pulling up. We continue to push from the top while taking up the slack by pulling on the cord at the bottom Just loose enough at the top there, a little bit of slack, and we’ll attach that screw. Now, when attaching the spout for this water line, we want to make sure that we line up this little locating rib on the bottom of that housing, into the slot on the actual air paddle.

With that lined up, that will sit flush, and then we can install that screw. We leave just a little bit of slack so we can line it up. Tighten it securely but be careful not to over-tighten it. We make sure that it’s lined up straight.

Now, we’ll go to the bottom of the door and detach the nylon cord that we had attached to the water line.

We’ll begin by removing the tape. We’ll discard all that. I’m actually going to reinstall that cam, so slide the tubing through it.

Line it up in the bottom of the door, then press it into place, reinstall the retaining screw.

There’s a small shoulder on that bolt, so we need to make sure that we line that up perfectly centered to allow that bolt to sit firmly on the cam. We’ll pivot that doorstop around and put the remaining screw in that. Tighten that securely.

Now that we have that all secure, before we put the door back onWe’re going to inspect the end of that water line, to make sure that we didn’t do any damage to it as we pushed it through that opening.

Make sure that we have a nice clean square cut on the end of it. That there is no damage in that area. We’ll also want to clean up any tape residue to ensure that the compression fitting secures it properly.

Once we’ve done thatWe’re ready to put the door back onto the refrigerator, and you should have somebody help by guiding that water line down through the lower hinge to make sure that we don’t damage it.

Next, we want to carefully line up that water line, insert it down through that lower hinge and then make sure that wouldn’t get any kinks in it. Then position the door up against the cabinet, and then we can secure that upper hinge. Just pivot that hinge into position. We’re going to put in one of those bolts, just to hold it in place.

not easy to push

Use caution when installing these bolts to make sure that they go in straight and that you don’t cross-thread them.

We’re not going to tighten them. We’ll just put them in loose until we ready to align that door. If you find any of those three bolts going in tight, just move over that door back and forth, which will allow that hinge to lineup better.

Now nextWe’re going to make sure that we have a nice even gap from top to bottom, so you can either push or pull that door to make sure that it’s square, it should also be flush across the top. I’ll hold it in position and tighten those bolts. Just double-check, and then we’ll secure them with a ratchet.

Make sure they’re tight. Next, we’ll reattach the two ground wires. We’ll just put that screw through both eyelets from those harnesses.

Make sure we don’t twist the ends of those ground wires, so that it puts a strain on the harness. Make sure there’s also slack on both sides. Then we’ll line up the main harness connector. There is a tapered end on both sides of that connector, line those up.

re going to put

Press them together.

Make sure that the locking tabs engage on both sides. We’ll take the hinge coverWe’re going to position that just forward of the front of the door, push it back so it catches on both sides of the hinge and screw should line up at the back. We secure that and now we’ll go to the bottom of the door where we’ll reconnect the water line.

Again, we’ll just check that water line, make sure we didn’t do any damage to the end of that tubing. We’ll fit the compression nut onto the new tubing. Fit it into the union, then just slide that nut down until you can start threading it. Tighten it securely.

We’ll just tuck that in on the top of the filter housing.

We’ll take our kick plate and we’ll line up the connectors on the end of these spring clips. Then just bump them into place. We’ll close up the doors.

We’re ready to reconnect the power, and your repair is complete.