Whirlpool BFG1J5040T3NOV 5K User Manual

24

IMPORTANT: The gas control valve/thermostat is a standard 
valve with wire leads that connect to a thermal switch. 
Removing the Gas Valve:
1.  Turn the gas control/temperature knob  to the “OFF” 

position (Figure 19).

2.  Turn off the gas at the manual shut-off valve on the gas 

supply pipe (Figure 3).

3.  Drain the water heater. Refer to the section of “Draining 

and Flushing” on page 20 and follow the procedure.

4.  Disconnect the igniter wire from the igniter button. 

Disconnect the thermopile, pilot tube, two wire leads at 
the thermal switch, and manifold tube at the gas control 
valve/thermostat (Figure 22). 

5.  Refer to “Gas Piping” (Figure 3) and disconnect the 

ground joint union in the gas piping. Disconnect the 
remaining pipe from the gas control valve/thermostat.

6.  To remove the gas valve, thread a correctly sized 

pipe into the inlet and use it to turn the gas valve 
(counterclockwise.) Do not use pipe wrench or equivalent 
to grip body.  Damage may result, causing leaks. Do not 
insert any sharp objects into the inlet or outlet 
connections. Damage to the gas valve may result.

Replacing the Gas Valve:
To replace the gas control valve/thermostat, reassemble in 
reverse order. IMPORTANT: This water heater has a 
resettable thermal switch installed. DO NOT attempt to disable 
or modify this feature in any way. When replacing the gas 
valve, thread a correctly sized pipe into the inlet and use it to 
turn the gas valve (clockwise.) DO NOT OVER TIGHTEN, 
damage may result. 
• 

Be sure to use approved Teflon

®

 tape or pipe joint 

compound on the gas piping connections and fitting on the 
back of the gas control valve that screws into tank.

• 

Be sure to remove the pilot ferrule nut from the new gas 
control valve/thermostat.

• 

Turn the gas supply on and check the gas supply and 
gas valve for leaks. Test the supply connections by 
brushing on an approved noncorrosive leak detection 
solution. Bubbles forming indicate a leak. Correct any 
leak found. 

• 

Be sure tank is completely filled with water before 
lighting and activating the water heater. Follow the 
“Lighting Instructions” on page 16. With the water heater 
lit check for leaks at the manifold and pilot connections. 
Bubbles forming indicate a leak. Correct any leak found.

• 

If additional information is required, contact the Service 
Department at: 1-877-817-6750.

TEFLON is a registered trademark of E.I. Du Pont De Nemours and Company.

5.  No leaks at pilot and manifold connection.
6.  Manifold door screws securely tightened. 
7.  Depress the button on the thermal switch.          
       

1.  Manifold door gasket properly sealed.
2.  Viewport not damaged or cracked.
3.  Flame-trap free of debris and undamaged.
4.  Two piece wire connector properly installed.

BURNER WILL NOT IGNITE

1.  Pilot not lit
2.  Thermostat set too low
3. No 

gas

4.  Dirt in the gas lines
5. Pilot 

line 

clogged

6.  Main burner line clogged
7. Non-functioning 

thermopile

8. Non-functioning 

thermostat

9.  Heater installed in a confined area

1. Light 

pilot

2.  Turn temp. dial to desired temperature
3.  Check with gas utility company
4.  Notify utility-install trap in gas line
5.  Clean, locate source and correct
6.  Clean, locate source and correct
7. Replace 

thermopile

8. Replace 

thermostat

9.  Provide fresh air ventilation

SMELLY WATER

1.  Sulfides in the water

1.  Replace the anode with a special anode

BURNER FLAME YELLOW-
LAZY

1.  Insufficient secondary air
2. Low 

gas 

pressure

3. Flue 

clogged

4.  Main burner line clogged
5.  Heater installed in a confined area
6.  Obstruction in main burner orifice

1.  Provide ventilation to water heater
2.  Check with gas utility company
3.  Clean, locate source and correct
4.  Clean, locate source and correct
5.  Proper fresh air ventilation
6.  Clean or replace orifice

PILOT WILL NOT LIGHT OR 
REMAIN LIT

1. Non-functioning 

igniter

2.  The thermal switch tripped

3. Thermopile 

connection 

loose

4.  Air in gas line
5. Low 

gas 

pressure

6. No 

gas

7.  Dirt in gas lines
8. Cold 

drafts

9.  Thermostat ECO switch open
10.  Pilot line or orifice clogged
11. Non-functioning thermopile
12.  Air for combustion obstructed

13.  Flammable vapors incident, Flame Lock

™

 

function utilized

1.  Replace igniter pilot assembly
2.  See Pilot Light Troubleshooting Flowchart

section

3.  Seat connector firmly in socket
4.  Bleed the air from the gas line
5.  Check with gas utility company
6.  Check with gas utility company
7.  Notify utility-install dirt trap in gas line
8.  Locate source and correct
9. Replace 

thermostat

10.  Clean, locate source and correct
11. Replace thermopile
12.  See maintenance section for inspection and   

cleaning of flame trap 

13.  Replace water heater, eliminate flammable 

vapors source. Call 1-877-817-6750