Wiring Harness Removal / Replacement

Important: Use only factory authorized replacement parts. If you lack the necessary skills to properly perform the installation, you should not proceed, but get help from a qualified service technician.

Tools required: Phillips Head Screwdriver.

Removing the Air Intake Chamber Box:

1.Set the gas control valve/thermostat to its lowest setting by pressing the “COOLER” and “HOTTER” buttons together at the same time holding for 1 second. Then press the “COOLER” button to the lowest setting (Figure 57).

2.Turn gas control switch to the “OFF” position (located right side of the gas control valve/ thermostat) and turn off the gas supply to the unit (Figure 58).

3.Disconnect the electric connection by unplugging the transformer from the wall outlet (Figure 58).

4.Remove the manifold cover/ outer door from the unit by depressing on the lower portion and pulling outward.

5.Unplug the 3-wire pressure switch/fan/sensor electrical connection of the wiring harness from the gas control valve/thermostat by depressing the lower portion of the snap clip to open and pulling down the connector (Figure 59).

6.Unplug the electric flag terminals and air pressure tubing from the pressure switch (Figure 60).

7.Remove the FV sensor by depressing the snap lock to open the FV sensor cover, slide the FV sensor out of the cover and unplug the electrical flag terminals connections (Note: place the FV sensor in a safe place as it will be reinstalled later) (Figure 60).

8.Using a phillips head screwdriver remove the 2 screws of the air intake chamber screen (Note: save screws for reinstallation later) (Figure 62).

9.Remove the air intake chamber screen by lifting upward and outward (Figure 62).

10.Please take note of the wire position routing around the fan inside the air intake chamber as this wire positioning will need to be duplicated upon installation of the new wiring harness (Figure 62).

11.Using a phillips head screwdriver, remove the 4 screws securing the air intake chamber box to the water heater’s side (also keeping these screws in a safe place for reinstallation later) (Figure 61).

12.Rotate the top of the air intake chamber box from left to right (only a few inches in both directions) while pulling outward at the bottom removing the air intake chamber box from the combustion chamber pipe saving the air intake chamber gasket for reinstallation (Figure 61).

Figure 57.

HOTTER COOLER