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Just to close this one out, I decided to try and change the valve as a last resort. It turns out it was that that was restricting flow, even though the motor and spindle were operating fine - the innards (diaphragm?) must have been buggered!

So the e majority of you were right all along! Moral of the story: just because all appears well, doesn't mean it is!

Thanks again.
 
Seems I spoke to soon, the error is back. I hear gurgling in the primary coil so it must be air that's trapped somehow because there's only water coming from the air release valve again.
 
Quick update for anyone still interested (or coming across this with a similar problem):

I now have enough flow to operate both CH and HW, I assume the air has settled and escaped.

However, now I get a trickling sound from the boiler when either CH or HW valve opens (eventually the trickling stops after ~1min). I assume this means there is air in the boiler (which will hopefully eventually find its way out)?
 

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