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8. Using the pilot screw removed earlier, attach the new
pilot/thermopile assembly. Reattach the burner to the
manifold using the screws removed earlier.
9. Reinstall the manifold component block in the
manifold door. Ensure that the pilot tube and wires
are positioned as shown in Figure 37.
MANIFOLD
COMPONENT
BLOCK
VIEWPORT
PILOT TUBE PASSES
THERMOPILE WIRES
THROUGH TOP
PASS THROUGH
HOLE OF MANIFOLD
BOTTOM HOLE
COMPONENT BLOCK
OF MANIFOLD
(LARGEST HOLE)
COMPONENT BLOCK
Figure 37
10. Carefully bend the new pilot tube to match the bend
of the manifold tube.
Note: When bending, DO NOT crimp or crease the pilot
tube.
11. Before you proceed to the next step, install the new
brass ferrule nut in the gas control valve/thermostat's
pilot tube opening, HAND TIGHT ONLY.
12. Install the manifold/burner assembly. Refer to the
"Replacing The Manifold/Burner Assembly" section
for instructions.
REPLACING THE MANIFOLD/BURNER ASSEMBLY
1. Check the door gasket for damage or imbedded debris
prior to installation (see Figure 35).
2. Inspect the viewport for damage and replace as
required (see Figure 35).
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 combustion chamber (see Figure 35).
4. Inspect the door gasket and make sure there is no
fi berglass insulation between the gasket and the
combustion chamber (see Figure 35).
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.
All manuals and user guides at all-guides.com
IGNITER WIRE
PASSES THROUGH
CENTER OF MANIFOLD
COMPONENT BLOCK
(SMALLEST HOLE)
www. gsw-wh .com
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/thermostat
(see Figure 32). Do not cross-thread or apply any
thread sealant to the fi ttings.
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 ferrule 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: Propane (LP) Gas systems use reverse (left-hand)
threads on the manifold tube.
7. Connect thermopile connector to the gas control valve/
thermostat (see Figure 32).
8. Reconnect the igniter wire (see Figure 32).
9. Turn "ON" the gas supply to the water heater at the
manual gas shut-off valve (see Figure 1).
10. Follow the lighting instructions on the label or see
"Lighting Instructions" to restart 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 forming
indicate a leak. Correct any leak found.
11. Verify proper operation, then replace the outer door.
WARNING
Explosion Hazard
Tighten both manifold door screws securely.
Remove any fiberglass between gasket and
combustion chamber.
Replace viewport if glass is missing
or damaged.
Replace manifold component block if miss-
ing or removed.
Replace door gasket if damaged.
Failure to do so can result in death,
explosion, or fire.
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