Site prep & safety
Shut off gas, power, and thermostat
Protect floors and work area
Remove old furnace
Disconnect gas line, venting, electrical, and duct connections
Remove furnace safely
Plenum fabrication & installation
Build supply plenum (metal box on top of furnace)
Build return plenum (air coming back to furnace, if needed)
Seal all joints with mastic/tape to prevent air leaks
Ensure correct airflow size and transitions to existing ductwork
Set new furnace
Level furnace and secure in place
Connect to supply and return plenum
Gas & venting
Connect gas line with shutoff and drip leg
Install flue or PVC venting (depends on furnace type)
Test for gas leaks
Electrical & controls
Connect power and ground
Wire thermostat and safety switches
Condensate drain (high-efficiency furnaces)
Install drain trap and tubing
Route to proper drain location
Indoor coil (evaporator coil)
Install coil above the furnace inside the plenum
Seal coil cabinet tightly to prevent air loss
Ensure correct airflow direction
Outdoor condenser
Place condenser on concrete or composite pad
Level and secure unit
Maintain proper clearances
Refrigerant line set
Run copper suction and liquid lines
Insulate suction line
Braze connections with nitrogen to prevent contamination
Condensate drain
Install drain line from coil
Add safety float switch (recommended)
Electrical
Install disconnect box near condenser
Run high-voltage and low-voltage wiring
Vacuum & refrigerant charge
Pull deep vacuum to remove moisture
Charge system with refrigerant per manufacturer specs
Thermostat setup
Install or program thermostat
Set up cooling stages if applicable
Seal duct connections and plenums
Check airflow (CFM) and temperature split
Test heating, cooling, and safety controls
Verify proper plenum sizing and airflow balance
Clean work area and explain system operation