In the process of attempting to install a new gas valve, I found out my 47-year old tray was completely rusted in half.

Written on 6/29/2023 by Guest

Step 1: I shut off the gas supply to the heater.
Step 2: I disconnected the gas lines attached to the valve.
Step 3: I took a few pics of the wire connections to the valve before removing them.
Step 4: I removed the 5 or 6 screws holding the old tray to the heater housing.
Step 5: I pulled out the old tray, half at a time since it was completely rusted in half.
Step 6: I removed the 7 stainless gas burners from the large gas supply U-pipe (burner manifold).
Step 7: I then installed the large gas supply U-pipe (burner manifold) to the new tray from Inyo.
Step 8: I drilled out the welds on the metal piece holding the fusible link assembly and then drilled similar holes in the new tray so I could install it with stainless screws in the same general location as the old tray.
Step 9: I installed the new gas valve to the burner manifold.
Step 10: I installed the 7 gas burners to the tray and manifold nipples, first putting the back end of each burner into the slot on the tray and then pushing it against the tray until the front could slip on to its manifold nipple.
Step 11: I installed the 1/4" pilot light gas line and the Visoflame lighter tube 1/4" supply line on the new valve.
Step 12: I installed the tray back into the heater (after vacuuming all the rust and debris from the heater housing) with the original screws that I removed from the old tray and the wires in their respective places on the new gas valve according to the directions that came with the new valve.
Step 13: I installed the main gas supply to the left side of the new gas valve.
Step 14: I turned the gas supply shut-off back on and then lit the pilot as usual and turned the heater on.

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