Replacing the Manifold Assembly
Tighten both manifold door screws
Remove any fiberglass between gasket
and combustion chamber.
Replace viewport if glass is missing or
Replace two piece wire connector if missing
Replace door gasket if damaged.
Failure to follow these instructions can
result in death, explosion, or fire.
1. Check the door gasket for damage or imbedded debris
prior to installation.
Replace viewport if glass is
missing or damaged.
Failure to do so can result in
death, explosion or fire.
2. Inspect the viewport for damage and replace as
3. Insert the manifold assembly into the burner
compartment making sure that the tab of the manifold
tube engages in the slot of the bracket inside the
combustion chamber (Figure 28B).
4. Inspect the door gasket and make sure there is no
fiberglass insulation between the gasket and the
5. Replace the two screws, which secure the manifold
assembly door to the combustion chamber and
tighten securely. Once the manifold assembly door is
tightened, visually inspect the door gasket between
the manifold assembly door and the combustion
chamber for spaces or gaps that would prevent a
seal. 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 two wire leads to the thermal switch, the
manifold tubing, pilot tubing, and thermocouple to the
gas control valve/thermostat. Do not cross-thread or
apply any thread sealant to these fittings.
The thermocouple nut should be started and turned
all the way in by hand. An additional quarter turn
with a 7/16" open-end wrench will then be sufficient
to seat the lockwasher.
7. Reconnect the igniter wire.
8. Turn gas supply on and refer to the Lighting
9. Check for leaks by brushing on an approved
noncorrosive leak detection solution. Bubbles forming
indicate a leak. Correct any leak found. IMPORTANT:
All leaks must be fixed immediately.
10. Replace the outer door.
Piezoelectric Igniter System
The piezoelectric igniter system consists of the igniter
button, electrode, and wire. The pilot is ignited by an
electric spark generated when the igniter button is pressed.
The spark gap of 0.125 inch is set when the electrode is
installed at the factory. (See Figure 29). Use only factory
authorized piezoelectric igniter parts for replacement.
Natural Gas & L.P. Gas
* Note: Spark gap distance measured from electrode tip to pilot.
Testing the Igniter System
Turn off the gas to the water heater at the manual gas shut-
off valve. Watch the electrode tip while activating the igniter.
A visible spark should jump from the electrode. To avoid
shock, do not touch the burner or any metal part on the
pilot or pilot assembly. If no spark is visible, check the wire
connections and make sure the electrode is not broken.
Replace the igniter if defective. Dirt and rust on the pilot or
electrode tip can prevent the igniter spark. Wipe clean with
a damp cloth and dry completely. Rust can be removed
from the electrode tip and metal surfaces by lightly sanding
with an emery cloth or fine grit sandpaper.
Close-up inside view of
the combustion chamber.