American Water Heater 318935-003 - Manual (Page 25)

25
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
Thermopile
Connectors
Manifold
Component
Block
Pilot Tube
Igniter
Wire
Burner Door Opening
Retainer
Clip
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
Pilot/Thermopile Assembly
Pilot/Thermopile
Assembly
Igniter Connector
Pilot Thermopile
Thermopile
Connectors
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)
Thermopile
Connectors
Manifold
Component
Block
Pilot Tube
Igniter
Wire
Burner Door Opening
Retainer
Clip
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.