Napoleon Corrosion Due to Condensate or Combustion Issues

Visible rust flakes or corrosion inside furnace cabinet and on burners

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Safety Warning

This repair may involve working with high voltage components or water connections. Always unplug the appliance before removing any panels.

If you are not confident in your ability to perform this repair safely, we strongly recommend contacting a professional technician.

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Possible Causes

Improper condensate drainage, Flue gas recirculation, High humidity in furnace room, Inadequate combustion air

How to Fix / Troubleshooting

Safety first: Turn off power and gas before cleaning internal components.

  • Address moisture: Check and repair any condensate leaks from the trap, hoses, or drain line.
  • Vent inspection: Ensure the PVC venting is properly sealed and sloped, and that terminations are not allowing flue gases to recirculate into the intake.
  • Clean rust: Light surface rust on burners and cabinet can be brushed off with a wire brush. Severely corroded burners or heat exchanger surfaces require replacement.
  • Combustion air: Make sure combustion air openings or intake piping are not blocked.
  • Professional evaluation: Significant corrosion on the heat exchanger or burner supports should be evaluated by a technician for safety.
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Repair Difficulty

Hard 4/5

Required Part

Burner Assembly
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