American Water Heater 6510238 Replacing the Thermocouple, Replacing the Manifold Assembly

Replacing the Thermocouple

Important: Use only a factory authorized thermocouple for replacement.

1.Remove the manifold assembly as directed previously.

2.Remove the retainer clip from the back of the two piece wire connector. Remove the two piece wire connector from the manifold door. Remove the thermocouple (Figure 22).

3.Pull the thermocouple from the pilot assembly. (Figure 21 and 24).

4.Push the new thermocouple through the holes in the pilot bracket. (Thermocouple tube must be positioned below the pilot bracket.) Insert the thermocouple tube into the holes provided in the pilot assembly until it clicks into place.

5.Position the new thermocouple through the larger opening of the two piece wire connector (Figure 22). Be sure igniter wire is positioned through the small opening of the two piece wire connector.

6.See “Replacing Manifold Assembly” at the top of next column.

Figure 22: Two Piece Wire Connector Assembly
	Thermocouple	Other fittings not
		shown for clarity
Igniter	Retainer Clip
Wire
		Manifold Door
	Two Piece Wire Connector

Replacing the Manifold Assembly

Explosion Hazard Tighten 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 do so can result in death, explosion, or fire.

1.Check the door gasket for damage or imbedded debris prior to installation.

2. Insert the manifold	Figure 23
assembly into the
burner compartment
making sure that tip
of the manifold tube
engages with the slot
in the bracket inside
the combustion
chamber (Figure 23).

3.Inspect the door

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

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

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