4.Remove the screw that secures the pilot shield and pilot assembly to the pilot bracket (Figure 35). Keep the screw for future use.
5.Loosen the nut securing the pilot tube to the pilot assembly. NOTE: To prevent any bending of the pilot bracket, use pliers to hold the pilot assembly bracket while loosening the pilot nut.
6.Pull the pilot tube from the pilot assembly (Figure 35).
IMPORTANT: Be careful not to bend or alter the position of the pilot assembly components.
7.Using the old pilot/pilot tube assembly as a guide, bend the new pilot tube to match the old one. NOTE: Make only the bends closest to the pilot before going to the next step. DO NOT crimp or crease the pilot tube.
8.Push the new pilot assembly connectors through the hole in the manifold door where the two piece wire connector wilt be seated (See Figure 35). Reconnect the pilot tube and tighten the nut securing it to the pilot assembly. IM PORTANT: Keep the pilot orifice in the pilot when making the connection. Do not operate the water heater without the pilot orifice installed.
9.Reattach the pilot shield and pilot assembly to the pilot bracket.
10.Reattach the burner and secure with the screws
removed earlier. NOTE: See Figure 34 for correct burner orientation.
11.Position the new pilot tube through the largest opening of the two piece wire connector. NOTE: The largest opening should be located at the top position. The igniter wire should be located in the middle opening and thermopile wires in the bottom opening.
12.Reposition the two piece wire connector in the manifold door opening and secure it with the retainer clip.
13.Before you proceed to the next step, install the new brass ferrule nut in the gas control valve/thermostat's pilot tube opening. HAND TIGHTEN ONLY.
14.See "Replacing the Manifold/Burner Assembly."
Burner and other fittings
not shown for clarity.
Thermopile
Connector
_tainer Clip
Wire
Pilot Tube _ _
Two Piece / _
Wire Connector
FIGURE 35.
Pilot
Thermopile
Thermopile
Connector
Thermal
Connectors
FIGURE 36.
Cleaning the Combustion Chamber and Flame-arrestor
1.Follow procedure outlined in "Removing the Manifold/ Burner Assembly."
2.Use a vacuum cleaner/shop vac to remove all loose debris in the combustion chamber (Figure 37). Use compressed
air to clear any dust or debris that may have accumulated in the
COMBUSTION CHAMBER
FLAME ARRESTOR
DOOR GASKET
FIGURE 37.
3.Reassemble by following the procedure under "Replacing the Manifold/Burner Assembly."
Replacing the Manifold/Burner Assembly
Explosion Hazard
Tighten both manifold door screws securely.
Remove any fiberglass between gasket and combustion chamber.
Replace viewport if glass is missing or damaged.
Replace two piece wire connector if missing or removed.
•Replace door gasket if damaged.
•Failure to follow these instructions can result in death, explosion, or fire.
1.Check the door gasket for damage or imbedded debris prior to installation.
2.Inspect the view port for damage and replace as required.
3.Insert the manifold/burner assembly into the burner
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