Baxi Overheating Components / Foreign Material on Heat Exchanger

Furnace produces a burning smell or plastic smell when running

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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

Dust or debris burning off heat exchanger, Overheating wiring or connectors, Fan motor overheating, Plastic components too close to flue or burner

How to Fix / Troubleshooting

Safety: If you smell burning plastic or see smoke, turn off power and gas immediately.

  • Initial run-in: A slight smell on first use can be normal as oils burn off. This should dissipate quickly.
  • Inspect internals: With power off, remove the front cover and look for discoloured wiring, melted insulation, or foreign objects near the burner or flue.
  • Check clearances: Ensure no storage items or insulation are touching the Baxi furnace casing or flue.
  • Professional repair: Any signs of overheated wiring or components require inspection and repair by a technician.
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Repair Difficulty

Hard 4/5

Required Part

Internal Wiring Harness / Fan Motor
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