Replacing a Smart Combustion Wire Harness on Touchscreen Grills

Replacing a smart combustion wire harness? Take these steps.

Related Articles

• Wiring Harnesses - Touchscreen Grills
• Smart Combustion Motherboard & Cover Replacement Instructions
• Hot Rod Service Panel Replacement Instructions - Touchscreen Grills
• Lid Sensor & Light Replacements

What is a Smart Combustion Wire Harness?

The smart combustion wire harness delivers power to Lid Sensor and Flame Sensor and communicates between those parts and the motherboard. The third split is not connected to anything; it was originally intended to connect to a grease sensor, which was not included in the final design.

Applicable SKU

• KIT0889

Connected Parts

• Lid Sensor & Light Sensor
• Motherboard
• Flame Sensor Wire Harness

How to Replace a Smart Combustion Wire Harness

Take the steps below to remove and replace smart combustion wire harness.

 See Wiring Harnesses for visuals of the wiring diagram, and images of the individual harnesses.

 Before You Start

1. Make sure the grill is turned off and unplugged.
2. Remove the grease and ash keg from the grill (located inside the grill cabinet/ underside of the grill).
3. Remove Hopper Side Service Panel
   • Use a manual impact driver to remove 6 screws:
     • 2 on top
     • 2 below the hopper side rail
     • 2 on the bottom

Pro Tip: Removing the P.A.L Rail first makes this easier.

1. Access the Smart Combustion Wire Harness

1. Under the grease and ash keg opening, remove the metal plate (2 screws).
2. Cut the zip tie holding the wire in place.

2. Disconnect the Smart Combustion Wire Harness from the Flame Sensor Wire Harness

1. Located inside the grill cabinet.
2. Remove the igniter access panel by unscrewing the four screws. Be cautious of falling ash and pellet debris.
   .
3. Disconnect the Smart Combustion Wire Harness from the Flame Sensor Wire Harness
   .
4. Tape the new Smart Combustion Wire Harness to the old wiring (shown in image above) that goes towards the motherboard to help guide it during removal
   .
5. Connect the flame sensor harness to its connector on the new Smart Combustion Wire Harness.

Pro Tip:  The wire that connects to flame sensor is longer than wire that connects the lid sensor wire.

3.  Pull the Flame Sensor Wire

1. Inside the hopper assembly, find the original Smart Combustion Wire Harness.
2. Gently pull the wire toward the motherboard.
3. Optional: For easier access, remove the induction fan. This helps you feed and pull wires under the grill from the hopper side.

4. Disconnect the Old Wire Harness

Follow minutes 0:00-1:03 of the video below for visual on accessing the motherboard and replacing the Smart Combustion Wire Harness.                                 

To access and disconnect the Smart Combustion Wire Harness, follow these steps:

1. Open the hopper lid.
2. Inside the hopper, locate the front interior panel. You’ll see 4 screws holding it in place.
   1. Start by removing the bottom-left screw. This screw holds the pellet safety guard.
3. Remove the pellet safety guard.
4. Unscrew the remaining 3 screws.
5. Carefully pull the front interior panel away from the hopper to expose the internal wires and the back side of the lid sensor/light.

Pro Tip: This step can be tricky because the panel edges are close to the hopper corners. You can use a screwdriver to gently pry the panel away.

6. Locate and disconnect the wire harness connectors to the Smart Combustion Wire Harness (seen in time stamp 1:01 in video above).
7. Plug in the lid sensor to new Smart Combustion Wire Harness (the shortest wire in the harness).
8. Inside the hopper assembly, find the original Smart Combustion Wire Harness. It has green, black, red, and yellow wires.
9. Disconnect the old harness from Motherboard.
10. Connect new Smart Combustion Wire Harness to Motherboard

5. Reconnect and Test

1. Plug the grill back in.
2. Turn on the power.
3. Run a Self-Test & Diagnostic Test to confirm everything works.
4. Reassemble grill.