Replacing flow manifold - Worcester Greenstar Junior 28i

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My boiler developed a leak a few days back, and after doing some research on google I realized it was leaking from the flow manifold, which is apparently quite a common problem on this boiler. The manifold itself was covered in a white crud, so knew it could do with changing.

Anyways I managed to remove the hydraulic block in the boiler, and swapped out the manifold and o-rings, and put it all back together.

It's kind of working (not leaking now anyway!) but the rads around the house aren't really getting that hot.

I'm just wondering if there's something obvious I'm missing.

I did the following:

1. Replaced the manifold and put everything back together
2. turned mains water back on and filled the boiler to around 1.2 bar
3. went round the house and bled all the rads to let the air out
4. Filled the boiler back again to around 1.2 bar (it had dropped to around 0.5 bar after I'd bled the rads)
5. quickly went back round the rads to check there was no remaining trapped air

As I say, it's firing up properly and the rads are getting warm, but just not hot......the hot water is fine though, that's nice and hot.

Any suggestions?


Also, one other thing..... the part I ordered for the manifold was 87161063560

I replaced everything that came in the packet apart from one piece....I have no idea what it is or where it's meant to go.....any ideas what it is?

Worcester_bosch_greenstar_flow_manifold_-_part_n.png


 
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No one?

Well the boiler hasn't leaked yet so maybe it's not that important :D
 
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still got no idea what that piece was, but after "balancing" the rads they are all OK now :)
 
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I think your boiler has a room sealed case which a DIYer should not have opened.

As I recall that "bit" is associated with a screw towards the top left corner of that part of the boiler!

Seems none of the other engineers on here bother with it either!

Tony
 
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Thanks Tony... not 100% convinced it's for the block screw, as I used the rubber grommet thing (directly below the thing I'd arrowed in red in the pic) on that screw.

AGAS, I'm guessing by your comment that you already know I've not carried out any "gas safe" checks that a certified engineer would carry out, as I don't have the equipment to do that nor do I have the money at the moment to pay for a boiler engineer to do the same.... which is the same reason I didn't get a boiler engineer to fit the part... I'm skint at the moment :)

I certainly didn't disrupt the central gas pipe in any way, nor was anything else disrupted that could cause concern. I have a Nest Protect smoke/carbon monoxide alarm close by, and that's not given me any cause for concern.

Hopefully the annual inspection in July (when I finally will have some money) will confirm all is good.

I appreciate this is some people's trade, so the last thing they want is DIYers having a go at jobs the pro's normally charge for, but times are hard, and i can't afford to pay someone £200+ to do something I am both competent and confident enough in doing myself for £21... I know my limits, but this was pretty simple.
 
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I appreciate this is some people's trade, so the last thing they want is DIYers having a go at jobs the pro's normally charge for, but times are hard, and i can't afford to pay someone £200+ to do something I am both competent and confident enough in doing myself for £21... I know my limits, but this was pretty simple.

Hopefully the annual inspection in July (when I finally will have some money) will confirm all is good.
ye right :ROFLMAO::ROFLMAO:
. I'm skint at the moment :)
so that makes it alright then (y) maybe think further than your pocket for a CHANGE :)
 
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so that makes it alright then (y) maybe think further than your pocket for a CHANGE :)

Maybe you could think further than your own pocket AGAS?

You're clearly very concerned about the safety aspect of my boiler above and beyond any associated costs. Maybe you could come round and check it for me free of charge?

I'm guessing not, as you are clearly thinking about your own pocket!
 
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Maybe you could think further than your own pocket AGAS?

You're clearly very concerned about the safety aspect of my boiler above and beyond any associated costs. Maybe you could come round and check it for me free of charge?

I'm guessing not, as you are clearly thinking about your own pocket!
eh ?????
 
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Maybe you could think further than your own pocket AGAS?

You're clearly very concerned about the safety aspect of my boiler above and beyond any associated costs. Maybe you could come round and check it for me free of charge?

I'm guessing not, as you are clearly thinking about your own pocket!

Imho maybe he's got the thoughts of your family or whoever you live with (if anyone) as it's their lives you put in danger as well (y)
As for doing it for free, unfortunately we have to make a living too, you know so my kids and grandkids can eat, be clothed, have a warm home, you know? I don't feel that's unreasonable?
 
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Imho maybe he's got the thoughts of your family or whoever you live with (if anyone) as it's their lives you put in danger as well (y)
As for doing it for free, unfortunately we have to make a living too, you know so my kids and grandkids can eat, be clothed, have a warm home, you know? I don't feel that's unreasonable?

No it's not unreasonable at all. People have to earn a living just like I do and I don't begrudge anyone doing that. My point is that some jobs can be done easily (and safely) by competent people, and some jobs are best left to an expert.

In my opionion, this job falls into the former category. If you are aware of the inherent dangers of gas, carbon monoxide, hot water, pressurised systems etc, and you can read a guide that's not even a page long (https://www.worcester-bosch.co.uk/support/document/download/release/8716115166/12640 - page 51 remove hydraulic block) then why should I beg/borrow/steal to find the money to pay someone to do something that I can easily do myself?

The other poster has zero concern for me or my family.... he just doesn't like the idea that people are willing to have a go at doing something pretty straightforward, which means £200 hasn't gone to him or another fellow boiler engineers pocket.

My theory is that this type of issue (apparently quite common on the WB green stars) are his "bread and butter" and he probably earns a fortune every week swapping them out, so maybe a little concerned that someone with zero training has come on a "DIY" forum telling people how easy it is :D

Look just because I've replaced a leaking manifold, I'm not claiming to be a boiler expert... far from it! But it's just stupid to suggest that all boiler jobs are equally complex and therefore anything related to a boiler you shouldn't go near!

I replaced a diverted valve on my grandparents boiler about 4 years ago.... another job that probably saved my Nan and grandad £200 that was easy, but AGAS no doubt would disapprove of.

It's like a mechanic telling me not to go changing the oil on my car.... "it's all part of the engine and the engine is a very dangerous thing that should never be messed with!" ....no-one would stand for that!

Doing an oil change is not the same as fixing a blown head gasket is it?

The vast majority of people on here are decent hardworking people, who've got stuck on something themselves over the years and have reached out for a bit of advice on the forum and have been helped... so they pay it forward and help others. You also get the people in here who actually just like helping other people out.

Unfortunately you also get people who are scared their livelihood is at risk if people start having a go at doing simple jobs that they charge a lot of money for!

I like having a go at DIY stuff, but my day job is AV and IT.... any questions, I'm always happy to help people... sharing knowledge is one of the fundamental differences between humans and animals and is the main reason our civilisation advances.

It boils down to the individual.. I imagine if AGAS worked in IT and someone came on here asking for some advice about a virus on their PC, he would reply with,

"Should you really be messing with it? You could potentially be releasing ransomware to everyone you know including friends and family, risking their data which could also be passed on to businesses that could bring them to a halt, potentially putting thousands of people's livelihoods at risk..... perhaps you should be getting an expert look at this?" :cautious:

For those who helped with useful responses... thank you.... I hope I can one day help you out and return the favour.... for people like AGAS..... thanks for nothing mate (y)
 
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