Newmar Dutch Star – Furnace Igniter & Control Board Replacement

Newmar Dutch Star – Furnace Igniter & Control Board Replacement

by

Complete repair guide for the Newmar Dutch Star – Furnace Igniter & Control Board Replacement. Follow these steps to diagnose and fix the issue yourself.

Parts & Tools You’ll Need

Step 1: Diagnose Furnace Ignition Failure

Start by checking that your propane supply is on and that you hear the blower motor engage when the thermostat calls for heat. Use your digital multimeter to test for 12V DC power at the furnace control board connector—if you’re getting no voltage, your circuit board has likely failed. Listen for a clicking sound at the igniter electrode; a silent igniter combined with no spark indicates a failed electrode, while no clicking suggests a bad control board.

Step 2: Shut Down Systems and Disconnect Power

Turn off your RV’s main power disconnect switch and propane supply valve at the tank, then wait 5 minutes for residual propane to dissipate. Locate the furnace’s 12V DC power connector (typically near the control board) and physically disconnect the wire harness to ensure no power is present. Turn on your propane/CO combo detector alarm and allow it to cycle to verify it’s functioning before proceeding.

Step 3: Remove Access Panel and Inspect Components

Unbolt the furnace access panel (usually 4-6 Phillips head screws) and visually inspect the igniter electrode for cracks, corrosion, or discoloration—a white or brown crusty coating indicates electrode failure. Check the sail switch (small flapper near the blower outlet) for proper movement and cleanliness; a stuck or debris-covered sail switch can prevent ignition lockout. Photograph the wire harness connections before disconnection for reference during reassembly.

Step 4: Replace Furnace Igniter Electrode Assembly

Disconnect the two-pin connector from the old igniter electrode, then unbolt the mounting bracket (usually one 1/4-inch bolt) and carefully slide out the electrode. Position the new furnace igniter electrode into the combustion chamber mounting bracket, ensuring the electrode tip sits approximately 1/8-inch from the burner flame path. Secure the mounting bolt to 15-20 inch-pounds of torque and reconnect the two-pin igniter connector, ensuring contacts are fully seated.

Step 5: Replace Furnace Control Circuit Board

Disconnect all wire harnesses from the old control board by carefully pulling straight back on each connector—do not twist or force. Remove the 3-4 mounting screws securing the board to the furnace frame, typically located in the upper corners. Install the new furnace circuit board in the same orientation, secure with mounting screws, and reconnect each wire harness to its original position, using your reference photos to verify correct placement.

Step 6: Verify Sail Switch and Blower Motor Function

With the access panel still open, manually push the sail switch flapper to confirm it moves freely without binding—clean with a soft brush if dust buildup is present. Check the furnace blower motor (12V DC) for physical damage and ensure the connector is clean and free of corrosion. Spin the blower wheel gently by hand to confirm it rotates freely with no grinding noises or mechanical resistance.

Step 7: Perform Complete System Test and Verification

Reconnect the furnace 12V power connector and turn the main power switch back on, then enable propane at the tank. Set your thermostat 5 degrees above the current interior temperature to trigger furnace startup, listening for the blower motor to engage within 2-3 seconds followed by igniter clicking. After 30 seconds of operation, verify warm air is flowing from the vents; if the furnace shuts down after 15-20 seconds, check that the high-limit switch hasn’t tripped and reset the board per manufacturer instructions.