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Replace Gas Water Heater Thermocouple
 
You wakeup one morning and there is no hot water. What happened?
With time and usage, the thermocouple wears out and needs to be replaces.
 
Find what went wrong:
1)      Make sure that you paid your gas bill.
2)      Check if the other gas appliances work, i.e. gas fireplace, gas stove, …
3)      If the other gas appliances work then the issue is with the Water Heater.
4)      If the other appliances do not work or you do not have other gas appliances, call your gas provider and make sure that, they did not cut your gas supply.
5)      If you have verified that gas is being delivered, then again the issue is the Water Heater.
6)      Your Options are:
                                I.      Change the water heater (depending on the size of the tank that will be on average $1200 task),
                             II.      Call Service Company (on average that will be about $300) that if he/she will not talk you into spending more on unnecessary services.
                           III.      DIY (that will be 30 minutes + $10 Parts + Trip to a Hardware Store, i.e. Home Depot, Lowe’s, etc.)
7)      If you make more than $300 per hour, please, call a technician (you can afford it and they have to make living too, at least you will be informed and you know the scope of the problem). Else, follow these steps for DIY (Do It Yourself).
 
Procedure:
  1. Turn off the gas supply to the water heater , usually, the shut off valve is located beside the water heater on the gas supply pipe,
  2. Locate the gas control valve/thermostat. Depress and hold the lock tab located under the gas control knob on the right. Rotate the gas control knob on the gas control assembly clockwise until OFF.
  3. Remove the outer door (cover) under the gas control assembly.
  4. Loosen the two screws securing the manifold door assembly (do not totally remove the screws and plastic retainer washers from the manifold door).
  5. Disconnect the thermocouple, manifold tube and pilot tube from the gas control assembly. Be careful, some are right hand thread and others are left hand thread (usually you need 3/4" and 7/16” wrenches), your model may require different wrench size. Once the tubes are loose, carefully pull the igniter wire from the igniter button.
  6. Free the three tubes from the gas control assembly by grasping the manifold tube and pushing down slightly. Remove the manifold assembly from the burner compartment.
  7. It is a good idea at this point to clean the flame arrestor and chamber (use toothbrush, vacuum, small broom, etc.).
  8. If a retainer clip is securing the wire connector to the manifold door, remove the retainer clip using flat screwdriver and rotate the screwdriver to raise the clip. (Keep the two-piece wire connector and retainer clip for re-installation).
  9. Some water heater models have a clip securing the thermocouple to the pilot bracket. The clip may be attached with a screw or a nut. Remove the clip.
  10. Carefully pull the thermocouple from the pilot assembly and from the manifold door assembly.
  11. Bend the new thermocouple smoothly (do not kink or crease) to reduce the extra length (sometimes the thermocouple is pre-bent).
  12. Insert the tip of the new thermocouple through the hole in the front of the manifold door and route it in the same configuration as the old thermocouple.
  13. Insert the new thermocouple tip into the hole provided in the pilot assembly. Then push the thermocouple completely forward until it is seated against the pilot assembly bracket (an audible click is usually heard when the thermocouple is fully seated).
  14. If applicable, secure the thermocouple clip to the pilot assembly.
  15. Re-install the two-piece wire connector in the manifold door.
  16. Insert the manifold assembly into the combustion chamber.
  17. Tighten the two screws that hold the manifold door assembly.
  18. Reconnect the thermocouple, manifold tube, pilot tube, and igniter wire to the gas control assembly.
  19. Turn the gas supply on and refer to the lighting instruction on the outside of the water heater.

 

 

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