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Just to confirm, it's all working a treat. Thank you all once again for all your help and advice. It is really appreciated.

Quick update - I was fortunate enough to secure some help from an old friend of mine who visited earlier today. I'm not sure I understand how this has worked but he tells me he has replaced the diaphragm and the problem has been resolved. I'm at a loss as to how it was working fine for CH but...

@Agile No, I have not removed the pump at any stage.

@DP thank you for following up. I haven't abandoned the post (nor the problem) but being back into the working week means I have very little time to work on this. I will update you as soon as I have anything worth saying but for now all I can tell you is that the problem is still there and I...

I did indeed. That was one of my first thoughts.

Hi @Agile I have indeed. I loosened off the screw until the water flow was steady and sadly that didn't resolve my issue.

I was kind of hoping the spindle issue might give some clue as to where the restriction is but I guess that was wishful thinking!

Thanks @ianmcd - I can't thank you enough. I'm hoping the part movement of the spindle might be the clue to solving this mystery!

Huge thanks to @ianmcd - you are a real star and I cannot thank you enough for all your help and time with this. I tested the diverter valve and it appears to be working. I also tested the flow switch sensor with a magnetic screwdriver and that also seems fine. Sadly still no HW on demand...

@ianmcd a pin inside the diverter valve actuator you mean?

@ianmcd Same issue. I open the hot tap and nothing happens - the boiler doesn't fire up and it's just a stream of cold from the tap

@ianmcd Ok so with CH off and hot tap open, nothing gets hot. The boiler doesn't fire up at all like this. If I turn the CH off, hot top open and override the flow switch then I get hot water no problem.

Thanks @ianmcd Can I check - when you said 'when you run a hot tap does one of the CH pipes get hot ?' did you mean overiding the flow switch so I get hot water or just open up the tap and let it run cold?

Let me check...

Do you mean in the boiler or at a radiator?

Ok, thanks Ian. Yes the pump definitely runs when HW only is selected and I open a tap. Is there another way I could clear the blockage?

Hi DP, everything was working ok until I switched the HE so that would lead me to think air in the system then. Any suggestions how to clear it?

Yes, definitely. It only fits one way.

Still no good. Any other suggestions?

Good morning, I tried running the DHW for 15 minutes last night but no luck on shifting the blockage. I'll try it again this morning and update shortly.