A.O. Smith GP 6 40YPC T 100, PCG6240T403NOV 100, PCG2J5040T3NOV 100 Undue Pressure or Sudden Force

25.	Install the air intake chamber screen, ensuring that
	the prongs of the lower portion of the air intake
	chamber screen are in place in the holding slots.
	Using the 2 screws removed in step 8, secure the
	air intake chamber screen (Figure 65).
26.	Check the air pressure tubing to the fitting on the
	of the air intake chamber box and route tubing
	in molded inlaid of the air intake chamber box
	(Figure 63).
27.	Reinstall the air intake chamber gasket (removed
	in step 12) on the back lower portion of the new air
	intake chamber box (Figure 66).
28.	Install the new air intake chamber box to the
	combustion chamber pipe. Using a small amount
	of soapy water will help. Do not get any water
	or soapy water on any electrical connections
	or gas control components (Figure 67). NOTE:
	UNDUE PRESSURE OR SUDDEN FORCE
	SUCH AS HAMMERING OR BEATING ON
	THE AIR CHAMBER BOX WITH ANY OBJECT
	INCLUDING YOUR HANDS WILL DAMAGE THE
	AIR INTAKE CHAMBER BOX AND RESULT IN
	FAILURE TO THE HEATER’S OPERATION.
29.	Install the air intake chamber box by rotating
	the top of the air intake chamber box from left to
	right (only a few inches in both directions) while
	pressing on the bottom portion of the air intake
	chamber box. When properly installed the air
	intake chamber box will be in place against the
	water heater’s side aligning with the screw holes
	(Figure 67).
30.	Secure the air intake chamber box to the water
	heater’s side by reusing the 4 screws removed in
	step 11 (Figure 67).

Figure 65.

INSTALL THE AIR INTAKE

CHAMBER SCREEN.

Figure 66.

REINSTALL

CHAMBER GASKET

AIR INTAKE

CHAMBER BOX

31.	Plug in the electrical flag terminals into the air
	pressure switch (Figure 60).
32.	Reinstall the FV sensor removed in step 7, by
	depressing the snap lock to open the FV sensor
	cover, route wiring through sensor cover, plug the
	electrical flag terminals connections to the FV
	sensor and slide the FV sensor back inside and
	close the cover (Figure 60).
33.	Connect the air pressure tubing to the pressure
	switch (Figure 60).

Figure 67.

ROTATE FROM

LEFT TO RIGHT

INSTALL SCREWS

34.	Attach the 3-wire wiring harness connector to the
	gas control valve (Figure 59).
35.	Check the air hose tubing connection to the
	pressure switch to ensure the tubing has not
	loosened up or pulled off (Figure 60).
36.	Turn on the electrical and the gas supplies to the
	water heater. Plug in the electric connection from
	the transformer to the electric outlet (Figure 58).
37.	Restart the water heater by following the
	directions on the “Lighting and Operating
	Instructions” label located on the front of the water
	heater.
38. Upon verifying proper operation of the water
	heater, replace the manifold cover/outer door.

AND

PUSH INWARD

36