Suburban 161156 / 525012 Pilot Burner & Thermocouple Assembly

The Suburban 161156 Pilot Burner Assembly is the OEM pilot assembly used on select Suburban SW-Series pilot-ignition RV water heaters. It includes the pilot burner and thermocouple components required to maintain and monitor the standing pilot flame.

The original 161156 part number has been superseded by Suburban 525012, the current service kit for these applications. The 525012 kit is identified as a burner, pilot, and thermocouple service assembly.

Models It Fits

The Suburban 161156 / 525012 is used on pilot-ignition SW-Series water heaters including:

• SW3P

• SW4P

• SW6P

• SW6PE

• SW6PR

• SW6PER

• SW10P

• SW10PE

• SW10PR

• SW10PER

Current Suburban parts listings specifically identify the 525012 for the SW6 and SW10 pilot-model families, while legacy parts breakdowns also document 161156 on the SW3P and SW4P.

Important SW3P Serial Number Fitment

The SW3P requires extra attention to serial number.

Suburban service information lists the 161156 pilot burner / thermocouple for SW3P units in the approximate serial range:

953401118 through 974400950

If you have an SW3P outside this serial range, verify the original pilot assembly before ordering.

Replaces / Supersedes

• 161156 – Original pilot burner assembly

• 525012 – Current Suburban service kit

The 525012 is the current replacement for the older 161156 in applicable models.

What the Pilot Assembly Does

The pilot assembly creates the small standing flame used to ignite the main burner on Suburban pilot-model water heaters.

The thermocouple sits in the pilot flame and generates a small electrical signal that keeps the pilot safety valve open. If the pilot flame goes out, the thermocouple cools and the gas supply is shut off.

This makes the thermocouple an important safety component as well as part of the normal ignition system.

Signs & Symptoms of a Failed Pilot Assembly or Thermocouple

A failing 161156 / 525012 may cause:

• Pilot will not stay lit

• Pilot lights while the control knob is held but goes out when released

• Pilot flame is weak or irregular

• Main burner will not ignite

• Thermocouple does not produce sufficient output

• Pilot burner is corroded or damaged

• Pilot tubing is damaged or restricted

• Water heater repeatedly loses the pilot flame

Before replacing the assembly, inspect the propane supply, pilot orifice, gas pressure, gas control valve, and burner area.

What Is Included

The current Suburban 525012 service kit includes the pilot-burner and thermocouple assembly and is approximately 12 inches long.

Estimated Install Time

Approximately 20–45 minutes, depending on access and the condition of the existing gas fittings.

Tools Required

• Open-end wrenches

• Screwdriver

• Basic hand tools

• Approved LP gas leak-detection solution

Installation Notes

Turn off the LP gas supply before servicing the water heater.

After replacing the pilot assembly, any disturbed gas fittings should be properly leak-tested before operating the appliance.

The thermocouple must be positioned correctly in the pilot flame. A thermocouple that is not adequately heated by the pilot can cause the pilot to shut off even when the new assembly is functioning properly.

Potential Issues

A pilot that will not stay lit does not automatically mean the thermocouple is bad. Similar symptoms can be caused by:

• Low propane pressure

• Dirty or restricted pilot orifice

• Improper pilot flame

• Loose thermocouple connection

• Faulty gas control valve / thermostat

• Debris or corrosion in the burner area

Proper diagnosis can help prevent replacing a functioning pilot assembly.

Product Specifications

Manufacturer: Suburban / Airxcel
Original Part Number: 161156
Current Service Kit: 525012
Part Type: Pilot Burner / Thermocouple Assembly
Approximate Length: 12 Inches
Fuel Type: LP / Propane
Application: Suburban SW-Series Pilot-Ignition RV Water Heaters
Common Models: SW3P, SW4P, SW6P/PE/PR/PER, SW10P/PE/PR/PER

Important Fitment Note

The 161156 / 525012 is for pilot-ignition Suburban water heaters. It is not used on DSI models such as the SW6D or SW10D, which use an electronic ignition system instead of a standing pilot.

For SW3P applications, verify the serial number before ordering because fitment changed during production.