Tom has successfully diagnosed my problem and provided a solution that I implemented, no thanks to Toyotomi USA or my Dealer. Unit seems within the normal range of sound during warm up, flame height and heat exchanger glow
In my opinion, if your 2007 L73 is still running well after 19 years, that's a testament to both the unit and the maintenance it's received over the years. You've already gotten excellent service life out of it.
The concern raised in the Toyotomi class about vent/chimney corrosion is a valid one. Even when a heater appears to be operating normally, internal corrosion in the concentric vent can potentially allow exhaust gases to migrate into the combustion air intake. Because this issue isn't always visible from the outside, it's worth having the venting system thoroughly inspected, especially at nearly 20 years of age.
As for rebuilding versus replacing, I'd look at the overall condition of the heater. If the heat exchanger, controls, fan motors, and cabinet are all in good shape, replacing wear items such as the burner mat and burner ring can still be a cost-effective option. However, once a unit approaches the 20-year mark, the availability of parts and the possibility of age-related failures in other components become factors to consider.
If it were mine, I'd have both the heater and the vent system evaluated before investing in a rebuild. If the venting requires replacement and additional major components are showing age, putting that money toward a new unit may make more sense long-term. On the other hand, if everything checks out well, a mat and burner ring replacement could reasonably extend the life of the heater for several more years.
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