Just an update, had several plumbers out and none of the knew what the problem was and afew where just interested in fitting a new boiler. In the end called out vaillant themselfs for a £260 fixed price repair, only things it didn't cover was main heat exchange and expansion vessel. On first visit the engineer pointed out that the seal on the main heat exchange had never been changed in 10 years and was blowing ( had it serviced every year by someone I thought was looking after my boiler!) so he changed it, he also replaced the pump, pressure release valve and the heat exchange plate but didn't solve the problem so he told me it must be the main heat exchange and the part alone cost £400!. He phoned the office and was amazed when they said they would change it for an extra £97, so I agreed and he came out the next morning and changed it and the boiler is now working like new, seems quieter and hot water flow is faster.
So for £357 I've had around £650-£700 of parts fitted not inc any labour, all parts guaranteed for 12 months. For an independent to do this I may aswell had a new boiler, can only recommend vaillant very helpful and engineers where brilliant can tell they know the boilers inside out, there was no quibble when changing all the parts for the £260, and then to change the main heat exchange for an extra £97 was amazing, thank you vaillant I feel like I've had a new boiler.