Replacing the Manifold Assembly

WARNING

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 embedded debris prior to installation.

2.Inspect the viewport for damage and replace as required.

3.Insert the manifold assembly into the burner compartment making sure that the manifold tab engages the slot inside the combustion chamber. See Figure 18.

FIGURE 18

Manifold Tab

Door Gasket

Burner

Slot

Viewport	Manifold Tab

4.Inspect the door gasket and make sure there is no fiberglass insulation between the door gasket and the combustion chamber.

5.Replace the two screws, which secure the manifold assembly door to the combustion chamber and tighten securely. Once the manifold assembly door is tightened, visually inspect the door gasket between the manifold assembly door and the combustion chamber for spaces or gaps that would prevent a seal. IMPORTANT: Do not operate the water heater if the door gasket does not create a seal between the manifold door and the combustion chamber.

6.Reconnect the manifold tubing to the thermostat. Do not cross-thread or apply any thread sealant to the manifold tubing.

NOTE: L.P. gas systems use reverse (left-hand) threads on the manifold tube.

7.Reconnect the Flame Sense/Hot Surface Igniter wire to the thermostat.

8.Turn gas supply on and refer to the Lighting Instructions.

9.Check for leaks by brushing on an approved noncorrosive leak detection solution. Bubbles will show a leak. Correct any leak found.

10.Replace the outer door.

Removing and Replacing the Gas Control Valve/Thermostat

IMPORTANT: Use only factory authorized replacement parts. Removing the Gas Control Valve/Thermostat:

1.Set the gas control valve/thermostat to its lowest setting by first depressing the COOLER and HOTTER buttons together and hold for 1 second. Then press the COOLER button until the WARM indicator light appears. (Figure 13).

2.Unplug the water heater from the wall outlet.

3.Turn off the gas at the manual shut-off valve on the gas supply pipe (Figure 2).

4.Drain the water heater. Refer to the “Draining and Flushing” section and follow the procedure.

5.Disconnect the flame sense/hot surface igniter wire from the thermostat. Disconnect the manifold tube at the thermostat (Figure 16). NOTE: L.P. gas systems use reverse (left-hand) threads on the manifold tube.

6.Refer to “Gas Piping” (Figure 2) and disconnect the ground joint union in the gas piping. Disconnect the remaining pipe from the gas control valve/thermostat.

7.To remove the gas control valve/thermostat, thread a correctly sized pipe into the inlet and use it to turn the gas control valve/thermostat (counterclockwise.) Do not use pipe wrench or equivalent to grip body. Damage may result, causing leaks. Do not insert any sharp

objects into the inlet or outlet connections. Damage to the gas control valve/thermostat may result.

Replacing the Gas Control Valve/Thermostat: To replace the gas control valve/thermostat, reassemble in reverse order. Use only factory authorized replacement parts.

•Be sure to use approved Teflon® tape or pipe joint compound on the gas piping connections and fitting on the back of the gas control valve/thermostat that screws into tank.

•Turn gas supply on and check for leaks. Use a chloride-free soap and water solution (bubbles forming indicate a leak) or other approved method.

•Be sure tank is completely filled with water before lighting and activating the water heater. Follow the Lighting Instructions.

•If additional information is required, contact the Service Department at: 1-800-456-9805.

TEFLON® is a registered trademark of E.I. Du Pont De Nemours and Company.

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