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Update: So a gas engineer came out from a different company and I explained the issue and told him what I thought the issue was based on the videos and advice given by ianmcd. He started by loosening the nuts slightly which seems to have solved the problem. He could see that grease had been used...

Thanks everyone. I came across these YouTube videos of exactly the same thing and these seems to suggest the same about the grease and the bolts, so here's hoping...

@ianmcd I PMd You earlier. Would be really grateful if you could let me know before they come out tomorrow. Thanks in advance

Well I've called and they are sending out an engineer from a different company that they use, so hopefully they will be able to sort it, but not holding my breath

Thanks. My insurance is through domestic and General who use a 3rd party heating company. The 3rd party company have said they can't do anything about it and to call my insurer. But that's pointless as they will just charge me an excess to send someone out who will probably say the same thing...

I don't know. I know it was a gasket kit 0020038679 and electrode kit 0020153950 that was fitted. That's all. He checked the bolts when he came earlier and they were all done up correctly

Please give me a clue as the noise is driving me round the bend. Could it possibly be anything to do with the way the nuts have been tightened up on the front of the heat exchanger?

They have just been to look and said its the heat exchanger expanding and contracting. So nothing can be done. Really ****ed off as it never made this noise before they replaced the burner seal and now it constantly making loud cracking noises

It's a vaillant ecotech plus 415

I will call in the morning. Trouble is, in the past they have refused to come out for 'noises' and i have an excess on my policy that I need to pay for them to come out. The noise is getting ridiculous. Happens every 30 seconds while the boiler is firing and goes on for a few minutes after it...

Hi I have a conventional boiler (non combi) with flue coming out the top and then going out through the wall. A couple of weeks ago I had a gas engineer service my boiler as part of my boiler cover. It was identified that a couple of seals/gaskets needed replacing and these were replaced a few...