Jacuzzi Overheating Components / Contaminants on Heat Exchanger

Jacuzzi pool heater emits a strong chemical or burning smell during operation.

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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

Debris or plastic melted on heat exchanger, Wiring insulation overheating, Soot buildup from poor combustion, Rodent nesting material burning

How to Fix / Troubleshooting

Safety first: Turn off power and gas immediately. Do not continue to operate the heater if you smell burning plastic or wiring.

Steps to investigate:

  • Visual inspection: After the heater cools, remove the front panel and inspect for melted plastic, leaves, or other debris on or near the heat exchanger and burners.
  • Check wiring: Look for discolored, brittle, or melted wire insulation. Replace any damaged wiring harnesses.
  • Combustion check (professional): Soot or a sharp exhaust odor indicates poor combustion. A technician should clean the burners and verify gas pressure and air supply.

Do not ignore persistent odors; they can indicate a fire or carbon monoxide risk.

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Repair Difficulty

Hard 4/5

Required Part

Jacuzzi Burner Assembly / Wiring Harness
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