Buderus GB142 Referenzhandbuch

Technical service bulletin

Heat Exchanger Replacement

Bulletin Number: TBG-35 | Model: GB142 series boilers

Data subject to change without notice | BTC 435002107 B | 02.2021

Heat Exchanger Replacement Procedure

Remove the cable plug from the gas control valve.

Figure 1

Remove both cable plugs [Fig.2, pos.1] from the fan unit.

Figure 2

Pull down on both retaining clips [Fig.3, pos.1] to open and

remove the burner cover.

1. 1.

Figure 3

Remove the burner [Fig.4, pos.1].

Figure 4

Disconnect the supply [Fig.5, pos.1] and return [Fig.5, pos.2]

sensors.

CAUTION: electrical short circuit

To prevent mix-ups, the supply sensor is marked by a

red sleeve on the side of the cable harness.

Figure 5

Disconnect the safety sensor [Fig.6, pos.1].

Figure 6

1 of 3

Bulletin Number: TBG-35 | GB142 Heat Exchanger Replacement Technical service bulletin

Data subject to change without notice | BTC 435002107 A | 05.2012

Disconnect the hot surface ignitor and ionization electrode

plugs.

Loosen the fastening screws [Fig.7, pos.1].

Pull the ground cable from the hot surface ignitor [Fig.7,

pos.2].

Dismantle the mounting plate [Fig.7, pos.3].

Figure 7

Remove both the hot surface ignitor and the ionization

electrode from heat exchanger [Fig.8].

Figure 8

Open latches [Fig.9, pos.1] on the condensate collector.

1 1

Figure 9

Remove the condensate collector.

Dismantle the tension spring [Fig.10, pos.1] between the

supply pipe and the heat exchanger.

Fully loosen nut [Fig.10, pos.2]. Remove both the nut and the

clip that was revealed beneath it from the old heat exchanger

and reinstall them on to the replacement heat exchanger in

the same location.



Figure 10

Loosen with one turn the nut [Fig.11, pos.1] between the

supply

Pull the supply pipe [Fig.11, pos.2] out of the heat exchanger.

Figure 11

Pull the combustion air supply and flue gas exhaust

connections on top of the appliance upwards to remove

them.

Loosen all fastening screws of the flue gas adapter.

Remove the flue gas adapter [Fig.12, pos.1] from the top of

the appliance.

Figure 12

2 of 3

Bulletin Number: TBG-35 | GB142 Heat Exchanger Replacement Technical service bulletin

Data subject to change without notice | BTC 435002107 B | 02.2021

Bosch Thermotechnology Corp.

65 Grove Street

Watertown, MA 02472

Tel: (866) 642-3198

Fax: (603) 965-7581

www.bosch-thermotechnology.us

Remove the heat exchanger by pulling forward on the bottom

end and then pushing it upwards [Fig.13].

Figure 13

Remove the flue gas collector from the old heat exchanger,

including the oval seal.

Put silicon on both sides of the new oval seal [Fig.14, pos.2], the

flue gas collector and the new heat exchanger [Fig.14, pos.1].

Figure 14

Reassemble the flue gas collector with the new oval seal to the

new heat exchanger.

Check if the new oval seal is placed correctly by opening the

condensate collector.

Install the new seal for the condensate collector [Fig.15, pos.2].

Figure 15

Install the new heat exchanger and all other parts in reverse

order of disassembly.

3 of 3

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