prior to installation (see Figure 14).
2. Inspect the viewport for damage and replace as required
(see Figure 20).
3. Insert the new manifold/burner assembly into the burner
compartment, making sure that the tab of the manifold
tube engages the slot of the bracket inside the combus-
tion chamber (see Figure 18).
4. Inspect the door gasket and make sure there is no
fiberglass insulation between the gasket and the com-
bustion chamber (see Figure 14).
5. Tighten the two screws that secure the manifold/burner
assembly to the combustion chamber. (Use a 1/4” nut
driver.) There should be no space between the gasket
part of the manifold door and combustion chamber.
Important:
Do not operate the water heater if the door
gasket does not create a seal between the manifold
door and the combustion chamber.
6. Reconnect the manifold tube (3/4” wrench) and pilot
tube (7/16” wrench) to the gas control valve/thermo-
stat (see Figure 19). Do not cross-thread or apply any
thread sealant to the fittings.
Important:
If you were supplied with a new ferrule nut
in a parts kit, follow these steps to connect the pilot
tube:
1.) Install the ferrule nut into the gas valve at the pilot
tube location, hand tight only,
2.) Insert the pilot tube into the f.errule nut until the tube
bottoms out, then tighten the nut with a 7/16” wrench
until the crimp connection seals to the pilot tube,
3.) Continue to tighten until the nut is tight in the gas
valve.
Note:
L.P. Gas systems use reverse (left-hand) threads
on the manifold tube.
7. Connect the white (-) thermopile wire to the gas control
valve/thermostat, then connect the red thermal switch
wires to the thermal switch on the manifold door. (see
Figure 19).
8. Reconnect the igniter wire (see Figure 19).
9. Turn on the gas supply to the water heater at the man-
ual gas shut-off valve (see Figure 4).
10. Follow the lighting instructions on the front of the water
heater. With the main burner lit, check for leaks at
the manifold and pilot connections by brushing on an
approved noncorrosive leak detection solution. If such
a solution is not available, use a mixture of hand dish
washing soap and water (one part soap to 15 parts
water) or childrens’ soap bubble solution. Bubbles form-
ing indicate a leak. Correct any leak found.
11. Verify proper operation, then replace the outer door.
MANIFOLD TUBE
TIP
BRACKET
SLOT
CLOSE-UP INSIDE VIEW OF
THE COMBUSTION CHAMBER.
Figure 18
Manifold Mounting Detail
Removing the Manifold/Burner
Assembly
1. Turn the gas control/temperature knob to the “OFF”
position (see Figures 10 & 19).
2. Before performing any maintenance, it is important to
turn off the gas supply to the water heater at the manual
gas shut-off valve. This valve is typically located beside
the water heater. Note the position of the shut-off valve
in the open/on position, then proceed to turn it off (see
Figure 4).
3. With the unit shut-off, allow sufficient time for the water
heater to cool before performing any maintenance.
IGNITER
WIRE
RED WIRE
(LEFT SIDE)
PILOT
TUBE
MANIFOLD TUBE
IGNITER
BUTTON
IGNITER
LEAD
WIRE
WHITE
WIRE
(RIGHT
SIDE)
GAS CONTROL/
TEMPERATURE KNOB
VAC
Figure 19
View On Gas Control/Thermostat
4. Remove the outer door.
5. Disconnect the following from the gas control valve/
thermostat: pilot tube (7/16” wrench), igniter wire (from
the igniter lead wire), and manifold tube (3/4” wrench)
(see Figure 19).
Note:
L.P. Gas systems use reverse (left-hand) threads
on the manifold tube.
6. Use needle nose pliers to disconnect the white (-) ther-
mopile wire from the gas control valve/thermostat (see
Figure 19). Next, disconnect both red thermal switch
wires from the thermal switch on the manifold door (see
Figure 20).
7. Grasp the manifold tube and push down slightly to free
the manifold tube and pilot tube.
8. Remove the screws (1/4” nut driver) securing the mani-
fold/burner assembly to the combustion chamber (see
Figure 20).
9. Carefully remove the manifold/burner assembly from
the combustion chamber. BE SURE NOT TO DAMAGE
ANY INTERNAL PARTS.
VIEWPORT
PILOT TUBE
THERMAL
SWITCH
MANIFOLD
DOOR
MANIFOLD COMPONENT
BLOCK
MANIFOLD
TUBE
OUTER DOOR
NOT SHOWN
MANIFOLD
SCREW (2)
GAS CONTROL
VALVE/THERMOSTAT
THERMOPILE
AND SWITCH
WIRE
CONNECTIONS
GAS CONTROL/
TEMPERATURE
KNOB
PIEZO IGNITER
BUTTON
Figure 20
View on Manifold Door
– 19 –
