For early (before 2003 ?) Disco 2's the oil separator in the valve cover is supposed to just lift out with a pair of pliers. (And the engine is not supposed to leak, and all the bolts are supposed to stay tight....)

After the pliers method fails, I've seen lots of questions about how else to get the brittle plastic part out. Here's what worked for me.

1) Drill a small hole about 1/2" deep or so into the plastic.

2) Screw a screw into it. I used an old sheet rock screw that happened to lying around. Should look something like this:



3) If you haven't already, spray the oil separator w/ choke cleaner or some other solvent. Actually, it might be best to use a tube and spray the solvent down the hole you just drilled before inserting the screw.....

4) Pull up on the screw. If you've gotten this far, it's probably b/c your separator is stuck in there pretty good. A gentle tug might not work. So, ...

5) Hold you pliers horizontal and grab the screw head deep in the pliers jaws. The intake manifold has a nice "shelf" right there where you can rest the tips of the pliers. (Upper right in photo.) Then you can lever the screw head out vertically and, fingers crossed, get it out in one-ish piece(s).

Here's what I got:


Picture isn't great, but look at the left end. Between the first and second baffle is a whole lotta crud. Here's after a bit of scraping:




Oh, and how are my valve covers, you ask? Smooth as a whistle and clean as a baby's behind:



Gonna clean and tighten them, but thinking about new vc gaskets in the not too distant future.

HTH.

 

Yep I mentioned using a small drill bit/wood screw in my FV308 PCV Write Up/Sticky. Makes removing that brittle plastic baffle a breeze.

 

Oops, missed that somehow......

 

No biggie!! Great pics & it never fails to find em almost completely clogged up!!