Worcester return manifold | Removal

This video will show you how to remove the Worcester return manifold. This part connects the pump, diverter, and DHW flow switch to the boiler.
This is not a job for the faint-hearted. Let me show you the steps to take to remove this component safely without any diasters. I also changed the PRV whilst I had the manifold removed from the boiler. Also, I recommend buying the flow sensor assembly as this usually crumbles when taking out of the old valve.
The parts I ordered (Worcester part numbers)
Return manifold: 87161064420
PRV: 87161064310
Flow sensor assembly: 87161064330

[@dombarnes7092]

I’ve changed loads of these and have never needed to remove the left hand block just pull it off the by pass then push it back on with plenty of grease🤷‍♂️ works every time👌

[@Carl-re6zb]

Hi Andy...
Pain in the butt job....
I have removed the return manifold without removing the flow side but an absolute pain with the limited space to manoeuvre the bypass connection..
Will remove the whole hydro block in the future as it seems a lot less fiddly.
Thanks for posting.

[@HomeglowLtd]

hiya Carl. It is a right pain. Always a job I dread doing.

[@poweravery4410]

Best boilers ever made 😂😭 them Worcester. Bet then installer have never changed this before.

[@paulmusther4219]

I believe there the best in the business all round .and yes I've changed the return block.

[@yensabi]

Get a hacksaw blade and cut through the right block an inch or so away from the bypass pipe , comes out nice and easy then , put bypass back into block before fitting and it will wiggle into the left hand side if you pull it forward a little bit towards you , it makes it a lot easier trust me...
don’t forget plenty of lube on those rings... 👍

[@darrenmackenzie1892]

Would you recommend reconditioned return manifold?

[@jameskeirle8114]

Fantastic, just what I needed

[@tommartin8538]

Hi Andy. The non return/bypass valve fell out when I removed the bypass pipe! And now I dont know which way round it should allow the flow. Am I correct in thinking the flow should be able to go from right to left through the valve? Thanks

[@Will-zv9xh]

Came here to find same answer. Bollocks

[@joncoke8208]

Nice video but the gasket wont affect the main heat exchanger so it main hex leaking

[@mattrowntree3359]

I did one today and managed to leave left hand block in .. a careful bit of manoeuvring and it goes .

[@MrRdt1970]

Hi all how much to do this replacement

[@ImHowardMoonsir1]

The part is £180 from wolsley and it'll take at least 3 hours (1 to diagnose initial problem then another 2 to fix it) so approx £400-450

[@martinj9251]

Dude use a gopro with a chest mount!