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Replacing a Water Heater Thermocouple or Flame Sensor

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Electronic Ignition Water Heater: Replacing the Thermocouple
Replacing a Water Heater Thermocouple or Flame Sensor

Thermocouple is fastened to the burner / pilot assembly

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Once the burner manifold assembly has been removed form the water heater you can access and replace the thermocouple as follows:
  • Slowly and firmly pull and twist the old thermocouple from the thermocouple bracket. It should come out fine if you use firm pressure.
  • Make sure you do not bend or modify the relationship with the pilot and the thermocouple bracket.
  • Remove the old thermocouple completely by pulling it through (from inside to outside) the rubber grommet seal or opening in the burner assembly manifold cover. Cut the old thermocouple if needed.
  • Take the old thermocouple to the hardware, home improvement or plumbing supply store to buy a replacement.
  • Insert the new thermocouple from the outside through the burner assembly manifold cover rubber grommet or opening.
  • Insert the thermocouple into the bracket from which you removed it, until it is fully seated or clicks into place.
  • The thermocouple tip must positioned so that the pilot flame envelopes the top 3/8” to 1/2 “ of the thermocouple tip.
  • Install a new burner manifold cover gasket or replace the old one if it is in good shape for reuse.
  • Place the burner in the combustion chamber and properly seat the unit.
  • Reinstall the cover assembly. Do not over tighten the screws or fasteners.

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