American Water Heater 318935-003 installation instructions Replacing the Pilot/Thermopile Assembly

Replacing the Pilot/Thermopile Assembly

1.Remove the burner assembly. See Removing the Burner Door Assembly Section.

2.Lift the retainer clip straight up from the back of the manifold component block (using a flat-blade screwdriver), then remove the manifold component block from the burner door (Figure 25). IMPORTANT: Be careful not to bend or alter the position of the pilot tube. Note the placement/order of the wires in the manifold component block.

Figure 25
Manifold Component
Block Assembly	Igniter
	Wire
Pilot Tube	Thermopile
	Connectors
	Retainer
	Clip
	Manifold
	Component
	Block
	Burner Door Opening

3.Turn the burner door assembly over till the pilot/ thermopile assembly is easily accessible.

4.Use a 7/16” wrench to loosen the nut securing the pilot tube to the pilot (right-hand threads). IMPORTANT: Be careful not to bend or alter the position of the pilot/ thermopile assembly components during the following steps. To prevent any bending, use a pair of pliers to steady the pilot/thermopile assembly bracket.

5.Locate and remove the screw attaching the pilot/ thermopile assembly to the burner and keep it for reuse later. IMPORTANT: Be careful not to bend or alter the position of the pilot/thermopile assembly components.

Figure 26	Igniter Connector
Pilot/Thermopile Assembly

Pilot Thermopile

Thermopile

Connectors	Pilot/Thermopile
	Assembly
	Pilot Tube
	(Ferrule Nut
	Not Shown)

6.Install the new pilot/thermopile assembly by routing the new igniter wire and new thermopile wire through the opening in the burner door (See Figure 25).

7.Use the screw removed earlier to attach the new pilot/ thermopile assembly to the burner door assembly. NOTE: Remove the pilot nut included with the new pilot/thermopile. IMPORTANT: Once the pilot nut is removed the pilot orifice MUST be kept in the pilot.

8.Connect the pilot tube to the new pilot and tighten the nut securely. To prevent any bending, use a pair of pli- ers to steady the pilot bracket. IMPORTANT: Keep the pilot orifice in the pilot when making the connection.

DO NOT operate the water heater without the pilot ori- fice installed.

9.Reinstall the manifold component block in the burner door. (See Figures 25). Be sure that the thermopile wires are positioned through the top opening of the manifold component block. The igniter wire should be positioned through the middle opening and the pilot tube through the bottom opening.

10.Follow the “Replacing the Burner Door Assembly” instructions to replace the burner door assembly.

Replacing the Pilot/Thermopile Assembly (50K Models)

1.Remove the burner assembly as directed previously.

2.Lift the retainer clip straight up from the back of the manifold component block (using a flat-blade screwdriver), then remove the manifold component block from the burner door assembly (Figure 27).

Figure 27
Manifold Component
Block Assembly (50K Models)	Igniter
	Wire
Pilot Tube	Thermopile
	Connectors
	Retainer
	Clip
	Manifold
	Component
	Block
Burner Door Opening

3.Locate and remove the screw attaching the pilot/ thermopile assembly to the burner and keep it for reuse later. IMPORTANT: Be careful not to bend or alter the position of the pilot/thermopile assembly components.

4.Pull the pilot/thermopile assembly from the burner door assembly. IMPORTANT: Be careful not to bend or alter the position of the pilot assembly components.

5.Use the old pilot tube as a guide and bend the new pilot tube to match the old one. Make only the bends closest to the pilot before going to the next step.

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