Worcester Incomplete Combustion / Flue Gas Spillage

Boiler casing or nearby walls show signs of soot or black staining, possible smell of exhaust gases.

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Safety Warning

This repair may involve working with high voltage components or water connections. Always unplug the appliance before removing any panels.

If you are not confident in your ability to perform this repair safely, we strongly recommend contacting a professional technician.

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Possible Causes

Blocked or disconnected flue, severely contaminated burner, incorrect gas-air ratio, failed seal on combustion chamber

How to Fix / Troubleshooting

Safety first: This is potentially life-threatening. Turn off the boiler and gas supply immediately, ventilate the area, and do not use the appliance. Install or check carbon monoxide alarms.

Homeowner checks:

  • Do not attempt to clean or repair the boiler yourself.
  • Evacuate the property if you feel unwell (headache, nausea) and call emergency services if CO poisoning is suspected.

Engineer actions:

  • Inspect flue integrity and correct any disconnections or blockages.
  • Check burner and heat exchanger for heavy contamination; clean or replace as necessary.
  • Test combustion with a flue gas analyser and adjust gas valve settings.
  • Replace any damaged combustion chamber seals.

The boiler must not be used until a Gas Safe engineer has declared it safe.

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Repair Difficulty

Professional Required 5/5

Required Part

Burner Assembly
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