Power Pack installation & removal

Drain fuel sump by unscrewing fuel sump drainage plug with 5mm hex key and allowing fuel to thoroughly drain into an appropriate container.  Replace drain plug when drained.

Turn Airtronic Burner upside down and disconnect primer port tubing at base of fuel pump.

Remove air solenoid coil retaining nut with 16mm wrench and remove air solenoid body.

Remove the metal air line using an 11mm wrench and set in a clean place.

Unscrew both metal fuel line hex nut connections with 11mm wrench.

Remove four or six screws (new burner) that hold the fuel sump to the lower fan housing using a 3/16 flat-tip screwdriver.

Slowly slide sump horizontally away from the pump to disengage the fuel crossover tube from the sump pump, taking care not to damage overflow safety device.  Remove the fuel sump and crossover tube.  NOTE: do not damage o-ring connections at both ends of crossover tube.

Disconnect all wires from the Airtronic Burner control box base with 1/8” flat-tip screwdriver

Pull control box wires through access hole in bottom of control box.  Note:  it is not absolutely necessary to disconnect all wires inside the control box base.  On all new burners the cabling connections are of quick disconnect type.  On the old burner, only the power cabling to the motor must be disconnected.  By disconnecting the quick disconnects at their respective components, the power pack can be lifted from the burner leaving the control box base wiring intact.  

Remove the two 10mm hex nuts, which hold the motor mounts to the upper fan housing, from their posts.  Remove the entire power pack (consisting of the motor, compressor, fuel pump, and blower wheel).

With 4mm hex key, loosen three pump retaining screws and lift out pump assembly.