Worcester 24CDi (old) replacement of Pressure Relief Valve

[AndrewKeen]

Hi

I need to replace the PRV on my 24CDi but I can't see how it comes out. Once I detach the overflow pipe it looks like I have to move it to the right about 12-14mm to remove it from the plastic manifold to it's left. However, the PRV sits very close to the boiler housing and there clearly isn't enough room to it's right.

Am I missing something or do I have to dismantle virtually the whole boiler to get it out?

You help greatly appreciated.

Regards

Andrew

 

[greemyamochop]

http://www.worcester-bosch.co.uk/in...e/24cdi-bf-discontinued-march-2005-literature

Page 20 of the installation and service pdf

 

[AndrewKeen]

Thanks greemyamochop

I have a copy but have downloaded it again in case mine is old/wrong, but can't see anything on p20 regarding the PRV, let alone the removal/replacement. I've been through it front to back a couple of times and can't find anything useful.

I'm looking at: installation-and-servicing-instructions-for-24cdi-bf--march-05.pdf

Any thoughts

Regards

Andrew

 

[AndrewKeen]

I've actually just found a section in another pdf I had for the 24CDi RSF model (p24). However, it simply says remove the clip and pul it out...which I simply can't do because of the clearance between the red knob and the boiler casing.

The only way I might be able to do it is by cutting the red knob off - the replacement has a far shorted red knob which will go in fine. Drastic stuff for something what should come off easily.

Any other thoughts appreciated.

Regards

A

 

[nickso]

have you tried to take it out yet? they sit close but they usually have enough room if you are removing the whole thing. removing only the plastic bit is usually harder.

biggest problem you will have is its bound to be stuck into the plastic manifold. you will likely need to twist it out. once it starts moving you can start to twist it down to get it out. if its too tight you will have to bend the case next to it, its pretty solid and difficult to move any great distance.

 

[AndrewKeen]

Nickso

I haven't tried yet but the clearance is 4mm between the knob and the casing and I need 16mm to get it out. Hacking off the red knob seems like the only option at the moment.

Regards

Andrew

 

[nickso]

hm, thats close right enough. as you say hack it off and if the new one has the flat face then all is good.

be careful with the plastic manifold, they go brittle. FYI do not ever remove the top nut off of the right manifold unless you have a replacement, especially if it has gone yellow, the nut often strips the thread off.

 

[AndrewKeen]

Nickso

Do you mean the nut that connects the PRV with the outlet pipe?

A

 

[nickso]

no, sorry i was just rambling in general about the plastic manifold. the prv outlet is fine to remove.