Water heater replacement

[kdenault]

We have a 6-gal Atwood G6A3 water heater on our Safari. It was working fine until it didn't! When we looked at the original hot water (when we had no hot water for morning showers), it was off and the plastic knobs on top of the gas valve were literally melted. Not sure if something clogged the exhaust or what happened???
Spoke with Dometic (now owns Atwood). They confirmed that the correct replacement parts for G6A3 water heater were:
Gas Valve, 91602
Main Burner, 92615
Pilot Assembly, 91603
Replaced all of the parts with new as the originals were severely rusted.
Got it lit, but the flame is very yellow and there was a lot of exhaust smoke. The instructions say to move the air shuttle on the main burner tube to the left to reduce the amount of oxygen which will turn the flame blue with a little yellow (the correct adjustment).
However, the air shuttle is already completely opened to the left in order to reach the connection coming from the bottom of the gas valve. There's no adjustment available on the air shuttle.
It seems as if the main burner tube of the new part is about 1" too short and letting in too much air.
Is there a different main burner that will work with this model that has a longer tube? Or could the excessive yellow flame and excessive exhaust smoke be caused by a clogged exhaust pipe.

[TG Twinkie]

Originally Posted by kdenault

We have a 6-gal Atwood G6A3 water heater on our Safari. It was working fine until it didn't! When we looked at the original hot water (when we had no hot water for morning showers), it was off and the plastic knobs on top of the gas valve were literally melted. Not sure if something clogged the exhaust or what happened???
Spoke with Dometic (now owns Atwood). They confirmed that the correct replacement parts for G6A3 water heater were:
Gas Valve, 91602
Main Burner, 92615
Pilot Assembly, 91603
Replaced all of the parts with new as the originals were severely rusted.
Got it lit, but the flame is very yellow and there was a lot of exhaust smoke. The instructions say to move the air shuttle on the main burner tube to the left to reduce the amount of oxygen which will turn the flame blue with a little yellow (the correct adjustment).
However, the air shuttle is already completely opened to the left in order to reach the connection coming from the bottom of the gas valve. There's no adjustment available on the air shuttle.
It seems as if the main burner tube of the new part is about 1" too short and letting in too much air.
Is there a different main burner that will work with this model that has a longer tube? Or could the excessive yellow flame and excessive exhaust smoke be caused by a clogged exhaust pipe.

Air shuttle completely open. You are getting too much air.
There should be a shuttle which you would move to close up the gap.
Can you remove the shuttle from the old unit?