American Water Heater Ultra Low NOx MODELS Installation Instructions And Use & Care Manual page 25

Replacing the Pilot/Thermopile Assembly
1. Remove the burner door 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 25).
Figure 25
Manifold Component
Block Assembly
Retainer Clip
Burner Door
Opening
3. Locate and remove the phillips screw attaching the pilot to
the pilot bracket, then pull the pilot/thermopile assembly
(including the igniter wire) out of the burner door assembly.
4. Using a 7/16" wrench, loosen the nut securing the pilot
tube to the pilot assembly (right-hand threads).
5. Pull the pilot tube from the pilot assembly (Figure 26).
IMPORTANT: Be careful not to bend or alter the position of
the pilot assembly components.
6. Using the old pilot tube as a guide, bend the new pilot
tube to match the old one. Make only the bends closest
to the pilot before going to the next step.
Figure 26
Pilot/Thermopile Assembly
Thermopile Connectors
Igniter
Connector
Pilot Tube
(Ferrule Nut
Not Shown)
7. Reconnect the pilot tube and tighten the nut securing it
to the pilot assembly. To prevent any bending of the pilot
bracket, use pliers to hold the pilot assembly bracket
while tightening the pilot nut.
IMPORTANT: Keep the pilot orifice in the pilot when
making the connection. DO NOT operate the water heater
without the pilot orifice installed.
8. Push the new pilot assembly connectors through the
opening in the burner door (See Figure 25).
9. Attach the pilot assembly to the Burner Door Assembly.
10. Position the new thermopile wires through the top opening
of the manifold component block (Figure 25). Be sure that
the igniter wire is positioned through the middle opening
of the manifold component block. Position the pilot tube
through the bottom opening of the manifold component
block.
11. See "Replacing the Burner Door Assembly".
Thermopile Connectors
Igniter Wire
Pilot Tube
Manifold Component Block
Thermopile
Pilot
Pilot/Thermopile
Assembly
WARNING
Explosion Hazard
Tighten all burner door screws
securely.
Remove any fiberglass between gasket
and combustion chamber.
Replace viewport if glass is missing or
damaged.
Replace manifold component block if missing
or removed.
Replace door gasket if damaged.
Failure to follow these instructions can
result in death, explosion, or fire.
25