🧰 Installation Guide — What Homeowners Should Know Before Replacing a Furnace
Replacing your home’s furnace isn’t just about swapping an old unit for a new one — it’s about optimizing comfort, energy use, and long-term savings. Whether your current furnace is on its last legs or you’re upgrading to a more efficient 92% AFUE Goodman model, understanding the installation process helps you plan better, stay safe, and get the most out of your investment.
As Savvy, I’m here to walk you through what every homeowner should know before a furnace replacement — from prep work and permits to airflow direction, eco-efficiency choices, and post-install testing.
🏡 1. Why Proper Furnace Installation Matters
Most people assume the hardest part of buying a new furnace is picking the right model. But in reality, installation quality determines 70% of your furnace’s long-term efficiency.
Even a high-efficiency system like Goodman’s 92% AFUE model can lose up to 30% of its rated performance if it’s improperly installed.
According to the U.S. Department of Energy, poor installation is one of the top causes of comfort issues, wasted fuel, and premature breakdowns. That’s why preparation — both mechanical and mental — is key.
🔍 2. Step One: Assess Your Current Setup
Before diving into the installation, start by evaluating what you already have.
🔧 Identify Your Furnace Type
Is your current unit:
-
Gas or electric?
-
Upflow, downflow, or horizontal configuration?
-
Single-stage, two-stage, or variable-speed?
Goodman’s GR9S920603BN is an upflow/horizontal gas furnace, ideal for basements, attics, and horizontal attic spaces. If your existing ductwork aligns with these configurations, your install will be much smoother.
🧭 Measure the Space
The cabinet width of 17.5 inches makes this Goodman model compact enough for tight utility areas — but confirm:
-
You have clearances per local code (often 1–3 inches on sides and back)
-
There’s enough space for ductwork connections and venting
-
You can easily access service panels for future maintenance
💡 Savvy Tip: Use a level and measuring tape to map out the furnace footprint before delivery. This helps installers plan duct transitions, venting paths, and gas line alignment.
🧱 3. Step Two: Know Your Airflow Direction
🌬️ Upflow vs. Horizontal Configuration
This Goodman furnace can be installed in two main orientations:
-
Upflow: Air enters from the bottom and exits through the top (common for basements)
-
Horizontal: Air enters on one side and exits the other (common for attics or crawl spaces)
Choosing the correct setup ensures balanced heating, even airflow, and longer system life.
Goodman provides detailed airflow diagrams in their product manual, but you can preview typical configurations on Energy Star’s installation guide for high-efficiency gas furnaces.
⚖️ 4. Step Three: Calculate Proper Sizing (BTU Load)
Before replacing your furnace, confirm that the 60,000 BTU capacity suits your home size and climate.
📏 General Sizing Formula
A rough guideline is:
30–60 BTUs per square foot, depending on insulation and region.
So, a 60,000 BTU system typically fits 1,000–2,000 sq. ft. homes depending on insulation and window quality.
🌡️ Regional Considerations
-
Northern U.S. homes: May need higher BTU output
-
Southern climates: Can downsize slightly due to milder winters
Use an ACCA Manual J load calculation or consult an HVAC professional for accuracy — this ensures you’re not over- or under-sizing your system.
🔄 Savvy Reminder: Oversizing doesn’t equal better heating. It causes short cycling, wasted gas, and uneven comfort.
🧾 5. Step Four: Check Permits, Codes & Rebates
Before any installation, homeowners should confirm local building codes and required permits. Many municipalities require inspections for gas lines, venting, and electrical work.
🏛️ Getting the Right Permits
Check your city’s building department or reference the International Residential Code (IRC) for national standards on gas furnace installation.
💲 Rebate Eligibility
High-efficiency models like the Goodman 92% AFUE may qualify for rebates or tax credits under the Inflation Reduction Act (IRA).
You can verify eligibility via the ENERGY STAR Rebate Finder or your local utility provider’s energy efficiency program.
🧰 6. Step Five: Prepare the Installation Area
🧹 Clear the Space
-
Remove debris, dust, and flammable materials
-
Ensure a solid, level base for the furnace
-
Verify drainage, especially if installed in a basement
⚙️ Verify Utility Connections
Before disconnecting the old furnace:
-
Turn off gas and electrical supply
-
Label existing ductwork and wiring
-
Inspect the venting system for cracks or rust (replace if necessary)
🔧 Pro Insight: If your venting or gas line setup is outdated, upgrading now improves both safety and efficiency.
For more on safety standards, visit NFPA’s guide on gas heating equipment.
🔄 7. Step Six: Removal of the Old Furnace
Removing your existing furnace involves careful disconnection of all utilities:
-
Shut off power at the breaker panel.
-
Close the gas valve and disconnect the gas line.
-
Detach duct connections and vent pipes.
-
Remove electrical wiring and thermostat connections.
Always ensure that combustion byproducts are safely vented before reconnecting new components. You can learn more about safe venting from the Home Ventilating Institute.
🚫 Savvy Caution: Improper disconnection of gas lines can lead to leaks or carbon monoxide exposure. Always use a licensed technician for this phase.
🔩 8. Step Seven: Positioning and Securing the New Furnace
Once your old unit is out, position your new Goodman furnace according to airflow direction.
🧭 Key Placement Tips:
-
Maintain manufacturer’s clearance from walls, ceilings, and combustible materials.
-
Ensure return and supply duct alignment matches the furnace collar.
-
Secure the furnace base to prevent vibration and noise.
🔒 Sealing Ducts
Leaky ducts waste up to 20–30% of heated air, per the U.S. Environmental Protection Agency.
Use UL 181-rated foil tape or mastic sealant to ensure airtight connections.
🔌 9. Step Eight: Electrical, Gas, and Vent Connections
⚡ Electrical Setup
Connect the power supply, control board wiring, and thermostat leads per Goodman’s wiring diagram.
Confirm grounding and secure connections to prevent arcing.
🔥 Gas Line Connection
-
Use a new flexible gas connector and apply pipe thread sealant.
-
Test for leaks using a soap solution — never open flame.
-
Verify the gas pressure meets Goodman’s specifications (usually 3.5" W.C. for natural gas).
🌫️ Venting & Combustion Air
The Goodman 92% AFUE furnace uses a PVC vent system for intake and exhaust.
-
Keep the intake and exhaust pipes at least 12 inches apart.
-
Slope exhaust pipes ¼ inch per foot toward the furnace for condensation drainage.
-
Terminate vent pipes per local code — usually 12 inches above ground and clear of windows.
For more venting layout examples, review ASHRAE’s residential ventilation standards.
🧊 10. Step Nine: Condensate Drainage Setup
High-efficiency furnaces produce condensate water during operation.
Install a drain trap and tubing to carry water to a floor drain or condensate pump.
💧 Pro Tip:
Add a float switch to the drain line — it automatically shuts off the furnace if the drain clogs, preventing water damage.
🔥 11. Step Ten: System Startup and Testing
After connections are complete, your technician will:
-
Check voltage and amperage draw
-
Test gas pressure and flame quality
-
Verify temperature rise (difference between supply and return air)
-
Confirm proper blower operation on all 9 speeds
🧠 Savvy Tip: Ask for a combustion analysis — it ensures your furnace is burning efficiently with minimal CO output.
🌡️ 12. Step Eleven: Thermostat Integration & Smart Controls
Pairing your Goodman furnace with a smart thermostat can boost efficiency by up to 10%, according to the EPA’s ENERGY STAR program.
Choose models like:
-
Google Nest Learning Thermostat
-
Ecobee Smart Thermostat Premium
-
Honeywell Home T9
These allow you to schedule heating, monitor usage, and even integrate with your solar setup — all while keeping your indoor climate consistent.
♻️ 13. Step Twelve: Eco-Friendly Disposal of Old Units
Don’t just toss your old furnace — recycle responsibly.
Most heating units contain recyclable metals like steel and copper. Check with:
-
Your local scrap metal center
-
Your utility company’s appliance recycling program
Responsible disposal prevents environmental contamination and may even earn a small rebate.
🧽 14. Step Thirteen: Post-Installation Maintenance Checklist
Once installed, schedule seasonal tune-ups to keep your furnace performing efficiently.
🧹 Monthly:
-
Check filters and replace as needed
-
Inspect thermostat settings
🔄 Annually:
-
Clean burners and flame sensor
-
Inspect venting and drain lines
-
Lubricate motor bearings (if applicable)
-
Check for CO leaks
🧩 Savvy Bonus: Add a MERV 8–11 rated air filter — it balances clean air with efficient airflow, improving both IAQ and system longevity.
💡 15. Step Fourteen: Common Mistakes to Avoid
Even with professional installation, homeowners sometimes unintentionally reduce efficiency by:
-
Blocking return vents with furniture
-
Using cheap fiberglass filters that clog quickly
-
Ignoring condensate drain cleaning
-
Setting thermostats too high for quick heat-ups (causing short cycles)
Keeping these in check ensures your Goodman system performs as intended — quietly, efficiently, and sustainably.
🌍 16. Why Goodman’s Design Makes Installation Easier
Goodman’s modular cabinet design and multi-speed blower simplify installation and long-term maintenance.
-
Compact 17.5-inch width fits tight spaces
-
Convertible airflow for flexible setup
-
Pre-wired control board reduces install time
-
Self-diagnostics help identify issues early
🌱 Savvy Takeaway: A well-installed Goodman furnace isn’t just a heat source — it’s a foundation for sustainable, energy-smart living.
🏁 Final Thoughts — Savvy’s Sustainable Comfort Checklist
Replacing your furnace is a perfect opportunity to rethink how you heat your home — efficiently, safely, and sustainably.
✅ Choose the right size for your home.
✅ Follow local codes and get professional installation.
✅ Seal ducts and optimize airflow.
✅ Pair with a smart thermostat for energy savings.
✅ Maintain it regularly for years of consistent comfort.
When done right, your new Goodman 92% AFUE furnace won’t just keep your home warm — it’ll help you save energy, reduce emissions, and make your comfort more sustainable year after year.
In the next blog, we shall learn more about Gas vs. Electric Furnaces — Which Is Better for Efficiency and the Planet?
