Worcester 24i Boiler Leaking

29 Apr 2008
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Boiler details: 24i RSF, GC No. 47 311 37.

I'm hoping someone else might have had this same problem. I rented my house out for a year or so and when I returned to it the boiler was leaking from one of the joints on the black plastic manifold. This part leaked a few years ago and I cured the leak by fitting a new manifold kit. This time I found that the kit appeared to be incomplete as it did not include all the O rings. I went back to the plumbers merchant but they said the kit does only come with 3 of the 4 or 5 O rings needed to do the job. I bought 2 extra O rings and attempted to fit the manifold today.
2 of the manifold joints fit onto copper pipes of about 20mm diameter and are secured by slotted spring clips. One O ring for these was included in the kit and the other I bought separately, as stated above. Both these seemed slightly thicker than the old O rings and I could not get the parts to fit together. I tried lubricating them with washing up liquid but it didn't help. I tried fitting the old O rings but that was also tricky as they seemed to have stretched slightly and were being forced out of their grooves. I eventually did get the new manifold in with the old O rings but it now leaks worse than ever.
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