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.

1.  See Wiring Harnesses for visuals of the wiring diagram, and images of the individual harnesses.
2. Ensure grill is off and unplugged.
3. Remove the hopper side service panel using a manual impact driver to remove 6 screws (2 located on top of the access panel, 2 below the hopper side rail, and 2 on the bottom of the access panel).
   • Pro Tip: Some customers find this easier if they remove the P.A.L Rail first.
4. Remove the grease and ash keg.
5. Under the grease and ash keg opening there will be a plate held in by 2 screws. Remove this plate to expose the smart combustion wire. Cut the zip tie to release the Wire.
6. Remove the Flame Assembly (located in the grill cabinet). Removal instructions are ion the first 20 seconds of video in this step.
   1. Tape off the Flame Sensor to the motherboard wire to use it as a guide and before you pull it through.
7. Gently pull the Flame Sensor wire towards the motherboard
8. Locate the Original smart combustion wire located within the hopper assembly. Ensure the Lid Sensor has been disconnected (Minutes 0:00-1:03 in video), and the motherboard connection has been disconnected.                                   
9. Disconnect the old Smart Combustion Wire (this wire is green, black, red,
   and yellow).
10. Plug in the new Smart Combustion Wire
11. Pull the new flame sensor connection towards the flame assembly.
12. Plug in both the remaining lid sensor and motherboard wires.
13. Plug grill back up, turn on power.
14. Run a Self-Test & Diagnostic Test.