Complete repair guide for the Keystone Cougar – Furnace Igniter & Control Board Replacement. Follow these steps to diagnose and fix the issue yourself.
Parts & Tools You’ll Need
- Suburban/Atwood RV furnace replacement unit
- Furnace igniter electrode assembly
- Furnace sail switch
- Furnace circuit board / control board
- Furnace high-limit switch
- Furnace blower motor (12V DC)
- Propane/CO combo detector alarm
- Digital multimeter (auto-ranging)
Disclosure: This post contains affiliate links. We may earn a commission on qualifying purchases at no extra cost to you.
Step-by-Step Repair Guide
Step 1: Diagnose Furnace Ignition Failure
Start by checking if your furnace clicks but doesn’t ignite, which indicates a faulty igniter electrode or control board issue. Turn off the propane supply and disconnect the negative battery terminal for safety before proceeding with any repairs.
Step 2: Remove Old Furnace Assembly
Locate your furnace unit beneath or behind the Cougar’s cabinets and disconnect all electrical connectors from the control board and blower motor. Unbolt the furnace mounting brackets and carefully slide the unit out, noting the positions of all connections for reassembly.
Step 3: Replace Igniter Electrode Assembly
Remove the old igniter electrode from the combustion chamber by unscrewing the mounting bracket and disconnecting its lead wire. Install the new igniter electrode assembly in the same position, ensuring it sits properly in the combustion chamber without touching any walls.
Step 4: Install New Control Circuit Board
Disconnect the old control board by removing its wire connections one at a time, taking photos to document the connections. Mount the new circuit board in the same location using the original hardware, then reconnect each wire to its corresponding terminal.
Step 5: Replace Safety Switch Components
Install the new sail switch and high-limit switch by removing the old ones and fastening the replacements in identical positions. These switches are critical safety components, so ensure they move freely and aren’t obstructed by any debris or insulation.
Step 6: Reconnect Blower Motor Assembly
Connect the 12V DC blower motor wires to the control board, matching the positive and negative leads to prevent motor damage. Ensure all connectors are firmly seated and the motor spins freely by hand before reassembling the furnace enclosure.
Step 7: Test System and Verify Operation
Reconnect the battery, restore the propane supply, and use your digital multimeter to verify 12V output at the igniter electrode. Turn on the furnace and listen for the ignition click followed by the blower fan; if heating occurs without error codes, your repair is successful.
Recommended Parts
| Part | Link |
|---|---|
| Suburban/Atwood RV furnace replacement unit | View on Amazon |
| Furnace igniter electrode assembly | View on Amazon |
| Furnace sail switch | View on Amazon |
| Furnace circuit board / control board | View on Amazon |
| Furnace high-limit switch | View on Amazon |
| Furnace blower motor (12V DC) | View on Amazon |
| Propane/CO combo detector alarm | View on Amazon |
| Digital multimeter (auto-ranging) | View on Amazon |