Whirlpool Residential Gas Water Heater Installation Instructions And Use & Care Manual page 23

Replacement Parts
IMPORTANT: The following maintenance procedures are
for the Flame Lock Safety System components and should
®
be performed by a qualified person.
Replacement parts may be ordered through your plumber
or the local distributor. Parts will be shipped at prevailing
prices and billed accordingly. When ordering replacement
parts, always have the following information ready:
1. model, serial, and product number
2. type of gas
3. item number
4. parts description
See pages 31-32 for a list of available repair parts.
Removing the Manifold Assembly
1. Turn off the gas to the water heater at the manual
shut-off valve (Figure 5).
2. Move the ON/OFF switch on the gas control valve/
thermostat to the "OFF"
position to turn off the water
heater.
(Figure 22).
3. Remove the outer door.
4. Remove the two screws
(1/4" nut driver) securing
the manifold door assembly
to the combustion chamber
(Figure 28).
5. Disconnect the pilot tube
(7/16" wrench), the igniter
wire, and manifold tube
(3/4" wrench) at the gas
control valve/thermostat.
Also use needle nose pliers
to disconnect the yellow
TCO wire leads from the thermal switch on the manifold
door. NOTE: L.P. Gas systems use reverse (left-hand)
threads on the manifold tube.
6. Grasp the manifold tube and push down slightly to free
the manifold and pilot tube.
7. Carefully remove the manifold assembly from the
burner compartment.
NOTE: Be sure not to damage internal parts.
Figure 28
Burner Assembly
Removal
Gas Control Valve/
Thermostat
Pilot Tube
Viewport
FV Sensor
Manifold Screw (2)
Figure 27
Gas Control Valve/
Thermostat
STATUS
ON
OFF
Pilot
Manifold
Igniter
Tube
Tube
Wire
Wiring Harness
Wiring
Harness
Manifold Tube
Thermal Switch
Manifold Door
Manifold Component Block
Removing the Burner from the
Manifold Assembly
Natural Gas Burner (Low Nox) & L.P. Burner
1. Take off the burner by removing the two (2) screws lo-
cated underneath the burner.
2. Check the burner to see if it is dirty or clogged. The burner
may be cleaned with soap and hot water (Figure 29).
Figure 29
Natural gas (Low NOx) and L.P.
Burner Assembly
Manifold Component
Manifold Door
Gasket
Burner
Pilot/Igniter - Flame
Sensor Assembly
Screws
Replacing the Pilot/Igniter - Flame
Sensor Assembly
1. Remove the manifold 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 manifold door (Figure 30).
Figure 30
Manifold Component
Pilot Tube
Block Assembly
Retainer
Clip
Igniter
Wire
Manifold Component
Block
Manifold Door
3. Using a 7/16" wrench, loosen the nut securing the pilot
tube to the pilot assembly.
Manifold Door Assembly
Thermal Switch
Block
Manifold Tube
Igniter Wire
Viewport
Pilot Tube
Manifold Tube
Manifold Door
Assembly
Pilot/Igniter-Flame Sensor Assembly
23