First off.
Thank you for having a site for those who like to help themselves.

I have enough general understanding/knowledge to get my self in trouble, this one has me a bit perplexed.

Coleman: 455 Seaspray
Ser: 455990101639
Service: 240vac GFI'ed at the breaker panel
Manufacture Date: 1-12-99

This spa has gone threw a severe freezing, I have had to replace 15' of 1 1/2 sch 40 pvc and 16 connections to repair leaking. All on the pump #2 side. pumps, heaters, and valves work as designed except for the one in problem #1.

Problem 1:
When using pump #1 (only) if i turn the knob for the "Air Controls" (to lessen confusion from this point on will be referred as "The Control Valve"

Water will pump out water from the top of The Control Valve assembly,
(Shown here with knob removed)


this valve is not cracked. This valve is located just to the right to the main power distribution box under the spa top.

This is not the "Air injector" system that has their own fittings and flanges piping and air pump.

All the tubing coming off this valve go to their own return jets mounted in the body of the spa, taking photos of this connection (return Valve) under the spa is impossible because I belive the person who sprayed the foam on this unit was paid by the gallon.

The control valve that all the hoses connect to looks like a Vacuum Tee you'd see on an old Chevy, just larger, This valve has a light rubber flapper valve built into the upper portion that acts as a check valve.
(shown here with hoses off.)

replacing this valve is NOT out of the question if I can be certain it's the problem.

The way I see this Air Control valve working is when the #1 pump is running the rear of the return jets will create a low pressure or vacuum drawing air towards the return jets and making tons of tiny little bubbles.
(this is pump #2 in action)



this is not happening. all return jets are set at full open at this point.

Problem 2: in the spa I keep finding small chunks of black thin foam rubber, have no idea where it could be coming from
, if there is something breaking down in the system it could be clogging the return jets creating a high pressure where there should be a low.

last question:
How do I remove the return jet inner cover with out breaking them. all of mine are adjustable from full on to full off.

Thank You again.
Rich