DP you don't seem to hold DIY'ers in very high regard, but the way I see it whatever you say Ive saved myself at least £400,
In my first post I suggested that you seek professional help because there are folk here, at least one DIYer, who dish out advice that lacks substance. This advice is very much like programmes on TV that do a house renovation in 60 minutes
My advice fell on deaf ears at which point I said crack on.
Going through your initial post it was clear where the failure was. I as a pro of 30 years still make mistakes but these mistakes do not cost the end user, glad to say these slips are few and far in between.
It is my practice to invite the end user to watch the repair, service or breakdown task to learn from what I do ( I care not if they will subsequently attemp repairs themselves- have plenty work to worry about that).
A failure like you had, first slip was draining the system.
Second was putting chemicals in- I take it you have carried out multiple fills and drains in order to remove from the system the debris that chemicals have suspended in system water. If you used Ferroquest/ Sentinel X800 and system has not been adequately flushed, expect the chemicals to play games with your new pump
Another point is vent and expansion pipes. These pipes cause so much confusion among regular plumbers and so called self claimed top engineers, no surprise you had modified pipes in order to resolve suspected problems. You can read another post about pump over in this section if you doubt what I say.
An easy approach on your boiler malfunction would have been to take temperature reading at various points to realise issue was lack of or poor circulation. Listening to the pump rather than suspecting pump was defective and changing it.
Have to say you are right in leaving the system open vented as sealing an old system ( unless valves are new and pipe fittings are secure) is asking for trouble.
I am all for a householder who is an able DIYer to have a go. Nothing wrong in that.
Come here to see what is going on and if I can, to help out. If I fail to understand the issue I will not offer advice that has no substance. As a gas engineer mainly doing repairs, see all aspects of breakdowns and as such have a good idea what is what but will never say I can fix every fault every time- far from it.