6.Position the new thermocouple through the bottom opening of the two piece wire connector (Figure 34). Be sure igniter wire is positioned through the small opening of the two piece wire connector.
7.
8.See “Replacing the Manifold/Burner Assembly.”
FERRULE NUT
THERMOCOUPLE
IGNITER WIRE
PILOT PILOT BRACKET
OTHER FITTINGS
NOT SHOWN
FOR CLARITY
RETAINER
CLIP
MANIFOLD TUBE
PILOT TUBE | MANIFOLD/BURNER |
| |
TWO PIECE | DOOR OPENING |
WIRE CONNECTOR |
|
FIGURE 34.
FIGURE 35.
Replacing the Pilot/ Pilot Tube Assembly
1.Remove the manifold/burner assembly. See “Removing the Manifold/Burner Assembly.”
2.Lift the retainer clip straight up from the back of the two piece wire connector (using a
IMPORTANT: Be careful not to bend or alter the position of the pilot tube. It will be used as a bending template for the new pilot assembly.
3.Take off the burner by removing the two (2) screws located underneath the burner. See Figure 33.
4.Remove and keep the screw securing the pilot assembly to the pilot bracket. (Figure 36)
5.Remove and keep the old pilot/pilot tube assembly.
6.Using the old pilot/pilot tube assembly as a guide, bend the new pilot tube and new thermocouple to match the old ones. NOTE: Make only the bends closest to the pilot before going to the next step. (Figure 36)
SCREW
OLD PILOT ASSEMBLY
PILOT TUBE | OTHER FITTINGS |
NOT SHOWN | |
| FOR CLARITY |
7.Route the new pilot tube, thermocouple, and igniter wire through the manifold/burner door opening. (Figure 34)
8.
9.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 thermocouple in the bottom opening. (Figure 37)
PILOT TUBE
IGNITER WIRE
THERMOCOUPLE
TWO PIECE WIRE CONNECTOR
FIGURE 37.
10.Reposition the two piece wire connector in the manifold door opening and secure it with the retainer clip.
11.Carefully bend the new pilot tube and thermocouple to match the bend of the manifold tube. NOTE: When bending, DO NOT crimp or crease the pilot tube or thermocouple. (Figure 34)
12.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.
13.See “Replacing the Manifold/Burner Assembly.”
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 38). Use compressed air to clear any dust or debris that may have accumulated in the
COMBUSTION CHAMBER
FLAME ARRESTOR
DOOR GASKET
FILTER 
IGNITER WIRE
THERMOCOUPLE
FIRST BEND(S)
FIGURE 38.
FIGURE 36.
3.Reassemble by following the procedure under “Replacing the Manifold/Burner Assembly.”
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