How to Replace Thermocouple on Water Heater?

Are you looking for ways to replace a thermocouple on the water heater?

If your water heater is not giving enough heat then it is time to replace the thermocouple and have a new one.

A thermocouple is a device that controls heat and protects you from severe cold by making the room temperature normal. If you replace this thermocouple, it will make your water heater work for a longer time.

You can do it as a DIY project with the right tools and material. In this guide, I will go through step-by-step information to make things easy for you.

Let’s start with the guide.

What is Thermocouple?

A thermocouple is a small electrical device that contains 2 different materials fixed in a way that they meet the same end.

How you replace the thermocouple depends on the ignition system of your water heater. The ignition system consists of 2 types including the electronic and standing pilot.

In both cases, the thermocouple is associated with the burner assembly.

In the standing pilot system, only the thermocouple and pilot are connected to the burner assembly but in the electronic ignition system, the thermocouple, pilot, and electronic igniter are also connected to the burner assembly.

It is the only difference that you should be aware of.

Points to Remember

• If you are not a pro in electronic work then you better not touch it with your hands because it might provide harm to you and your surrounding.
• Better leave this work for the professionals. However, if you have full knowledge of this work, you can make it a DIY project.

Tools and Materials Required for Thermocouple Water Heater

The list of tools that you should have if you are doing it as a DIY project includes:

• Screwdrivers
• Adjustable wrench or open-end wrench
• Utility knife (optional)
• New thermocouple
• Water-heater manifold replacement gasket
• Water Mixture and Dish Detergent

The process of Replace Hot Water Heater Thermocouple

Now you have gathered all the required accessories including tools and material, let’s move toward the steps needed to follow for this purpose. The steps include:

1. Detach Burner Assembly Cover

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In order to get access to the combustion chamber of the thermocouple, you might unfold or remove the burner assembly cover.

The cover is here to protect the burner, burner supply tube, pilot, electronic ignition, etc. The combustion chamber is sealed tightly and you have to lose it with extra care.

Remove the screws or bolts that are there to protect the cover plate. It might be screws or nuts or bolts depending on the water heater model you contain. Once they are removed, proceed to the next part.

2. Detach the Burner Assembly

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Now you have to remove the thermocouple connections for which you should have a burner supply tube. As you have already gotten access to burner combustion where you have to slightly remove the burner assembly.

While removing the burner ensure not to provide any harm to the internal components otherwise, you can destroy the entire burner combustion.

If you are facing a tough time removing the burner it might be due to the screws attached to the burner base. Deeply check the entire burner and remove the screws if any.

Once all the screws are removed, it will be easy for you to remove the burner as well.

3. Get Rid of the Cover Plate Gasket

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Now remove the cover Plate Gasket from the manifold cover plate. If it is in better condition, you can keep it in order to install once the thermocouple has been replaced.

However, if it is not in a good condition, it is better to buy a new one.

4. Pull Out Thermocouple

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Now you need to pull out the thermocouple in order to replace it with a new one. If you firmly put pressure then it will be easy for you to remove it from the mounting bracket.

However, ensure not to bend over the pressure between the thermocouple bracket and pilot. You can also cut down the thermocouple in order to remove it.

It is better to take the old thermocouple to the store in order to get the exact replacement. If you are planning to buy a new gasket, but it with the thermocouple.

5. Install the New Thermocouple

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Now comes the main work which is installing a new thermocouple for your water heater. You have to install the burner assembly cover through the grommet or opening.

Install the thermocouple in the mounting bracket and ensure that it has been fully fit. Once you are sure that it has been installed correctly, move to the next step.

6. Reinstall the Burner Cover

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The burner cover that you removed in order to detach the old thermocouple should be reinstalled again once you have installed a new thermocouple.

If the cover is in good condition, you can reuse the cover. However, do not overtight the screws. Now reconnect the valve and you are all done. It is how you can replace a new thermocouple as a DIY project.

How to Reconnect the Gas Control Valve

Once you are done with the installation you also need to reconnect the gas control valve. But how? Let’s talk about it below for a better understanding.

1. Reaffix the Gas Tubes

   Now connect the thermocouple, pilot supply tube, and burner supply tube to the gas valve. Ensure that the mounting nut should be only 1/4 turn tight on the thermocouple.

   Once, you have reaffixed all the gas tubes, turn on the gas. Before setting the gas control valve On, ensure to follow the instructions of the manufacturer.

   You have to set the temperature of the water heater as per the requirement.

2. Testing

   Once you are done with all the things, do not forget to test each tube and gas valve because sometimes there is a leakage issue that we ignore and which turns into the leading problem.

   You can do the testing by using soapy water. If any bubble forms, it means that the leakage issue is there. In such a case, make sure to tighten all the tubes.

FAQs – Frequently Asked Questions

Let’s have a look at a few frequently asked questions regarding the thermocouple gas heater. It includes:

Can I Replace a Thermocouple Myself?

Yes, you can do it if you are already aware of electrical work. However, if you have zero knowledge better avoid touching sensitive wires and tubes because it might provide harm.

Is it Hard to Change a Thermocouple on a Water Heater?

No, it is an easy process as mentioned in the guide in the detailed form. The new thermocouple only costs you $5 to $10.

How Do You Remove a Thermocouple to Replace it?

The first step is to affix the burner assembly cover to get access to all the tubes and main parts. From the cover, you have to remove the burner assembly, cover plate gasket, and thermocouple.

Once it is done, reinstall it and later reaffix the burner cover.

How Much Does it Cost to Replace a Water Heater?

If you notice that the water heater has stopped working and you need to replace it with a new one, it is better to spend some cost on it.

The new water heater only costs $811 to $1,566 depending on the size and brand as well.

Are Water Heater Thermocouples Universal?

The universal thermocouple has a length of 15 to 36 inches. However, if the length is 18 or 24 then you can make it universal by adding the universal kit.

Why Won’t My Pilot Light Stay Lit on My Hot Water Heater?

It might be due to the issue with thermocouples. In case, it is dirty or damaged, the pilot light will not be lit. If you are facing this issue, ensure that the thermocouple is working properly.

Final Words

It is easy to replace Thermocouple on Water Heater but you should have enough knowledge in order to do it at home. With the right tool and material, you can complete the installation process.

I have mentioned some easy-to-follow steps so that it eases your confusion.

If your water heater is not working as it used to be, the problem is surely in the thermocouple and it needs to be replaced. I hope this guide will help you replace the thermocouple easily in the future.