Zodiac Internal Water Leak / Heat Exchanger or Manifold Leak

Zodiac pool heater leaks water from the bottom of the cabinet.

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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

Cracked copper or cupronickel heat exchanger, Failed manifold gasket, Corroded header, Freeze damage

How to Fix / Troubleshooting

Safety: Turn off power and gas. Close isolation valves to the heater if installed. Water leaks can damage electrical components.

  • Identify leak source: Remove the front and side panels and inspect around the heat exchanger, headers, and plumbing unions while the pump is running.
  • Check unions and fittings: Tighten loose unions and fittings on the inlet and outlet. Replace O-rings or gaskets if leaking at connections.
  • Inspect heat exchanger: Look for visible corrosion, green/blue staining, or active dripping from the exchanger tubes or header joints.
  • Assess freeze damage: If the heater was exposed to freezing temperatures without proper winterization, cracks in the exchanger or manifold are likely and require replacement.
  • Replace components: A leaking heat exchanger or header typically must be replaced with Zodiac OEM parts by a professional due to gas and combustion sealing requirements.
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Repair Difficulty

Professional Required 5/5

Required Part

Heat Exchanger
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