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Removing the Burner Door Assembly
1.
Turn off the gas to the water heater at the manual
shut-off valve (Figure 2).
2.
Turn the gas control/temperature knob to the “OFF”
position (Figure 22).
3.
Remove the outer door.
4.
Remove the two screws (1/4” nut driver) securing the
burner door assembly to the combustion chamber
(Figure 24).
5.
Disconnect the pilot tube (7/16” wrench), the igniter wire
from the igniter lead wire, and manifold tube (3/4” wrench)
at the gas control valve/thermostat. Disconnect the sensor
wires (lift white lever outward, then gently pull the plug
downward). Also, use needle nose pliers to disconnect the
red (+) and white (-) thermopile wires from the gas control
valve/thermostat. See Figures 24 & 25.
GAS CONTROL VALVE/
TEMPERATURE SENSOR
THERMOSTAT
WIRE CONNECTION
THERMOPILE
WIRE
CONNECTIONS
PIEZO IGNITER BUTTON
VAC
MANIFOLD TUBE
PILOT TUBE
TEMPERATURE
VIEWPORT
SENSOR
OUTER DOOR
NOT SHOWN
BURNER DOOR
BURNER DOOR
SCREWS (2)
MANIFOLD COMPONENT BLOCK
FIGURE 24.
6.
Grasp the manifold tube and push down slightly to free the
manifold, pilot tube, and thermopile.
7.
Carefully remove the burner door assembly from the burner
compartment.
NOTE: Be sure not to damage internal parts.
SENSOR
VAC
WIRES
IGNITER
WHITE
BUTTON
WIRE
(RIGHT
SIDE)
IGNITER
LEAD
WIRE
PILOT
RED
TUBE
WIRE
IGNITER
MANIFOLD
(LEFT
WIRE
TUBE
SIDE)
FIGURE 25.
Ultra Low NOx Natural Gas Burner
Check the burner to see if it is dirty or clogged. The burner may
be cleaned with soft paint brush (Figure 26). Do not use a wire
brush or any tool that may damage the burner screen. Important:
Do not use the burner if the burner screen is damaged. NOTE:
Damage may be rips or holes in the burner screen. Discoloration
is normal.
PILOT ASSEMBLY
BURNER
USE BRUSH ON THIS SURFACE.
FIGURE 26.
Replacing the Pilot/Thermopile Assembly
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).
IGNITER
WIRE
PILOT TUBE
THERMOPILE
CONNECTORS
RETAINER
CLIP
MANIFOLD
COMPONENT
BLOCK
BURNER DOOR OPENING
FIGURE 27.
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 28).
IMPORTANT: Be careful not to bend or alter the position of the
pilot assembly components.
Page 24
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