I'm still not clear on this... I prefer to cut the top of the metal tube (the part that's in the valve cover that holds the plastic oil separator that needs to be removed) instead of widening the hole, but I'm not sure how much to cut it down by. Will 1/4" be enough? Will 1/2" be too much? I don't want to screw this up...

I'm also wondering how you can be sure you've put this part back into the valve cover properly - will it stop at a certain point or will it keep going? Does it matter as long as there's room to reattach the breather hose? Do you need to use anything to ensure it has a good seal? I'll have everything on Thursday and I'm hoping to attempt this on Friday or over the weekend.

I've also never understood how to reclamp the factory hose clamps. I can get them undone, but it seems you need a specialized tool to get them back how they were.

 

well ha now Im able to reply with some advice since now Ive done it lol. not perfect but I got it! for one its just a plug with a thick closed off end with hole in center at top.. after pulling it out of valve cover , i drilled through the existing hole to get all the old plastic separator bits out and i should have just slightly enlarged the hole with a larger bit to get it a nice flow through... that top end with hole in it is thicker than the sides of the metal housing ( tubing, nipple that the hose goes over) its embarrassingly easy once you understand the explanations lol anyway.. take off hoses.. twist and pull to get it out... pull out or drill out and clean out the separator plastic bits from that piece... open up the hole or just take off the top part any means u want.. its a couple inches long.. maybe 2" just take to very top off or open it up and be done with it.. tappity tap tap back into valve cover then push on hose and clamp it back on.. then goto the intake side and remove hose... unscrew the factory plastic connector into the intake plenum ( with crescent wrench is fine) then screw in the PVC valve.. slide hose back on and clamp it back and your done!

You know one observation ive noticed besides more engine pep and less smell, is that my oil pressure gauge was always erratic meaning reading kind of low then normal then low.. now all reading spot on! i wonder if any backpressure could make an oil pressure gauge read wonky.. hmm it never was too low just occasionally would read lower then Id expect

 

I did this mod almost 2 years ago and I didn’t read the part about drilling the hole a bit bigger, I just removed the plastic inside it lol. Oh well another small project to do.
Getting out my step drill bit

 

I’m going to drill mine out today to eliminate the restricted hole

anyone ever look at how the fresh air goes in for the pcv system , I’m assuming it’s on the drivers side ??

 

yes it does.

 

Is it safe to spray PB Blaster on the metal tube to help in removing it? Should I use silicone spray on this end as well, or just clean the area and reinsert the metal pipe once the plastic oil separator has been removed from it?

 

I have yet to have a tube that didn't loosen up with just a pair of pliers, and a cloth around it to prevent the pliers from digging into it. Twist back n forth and then as you twist pull up and it should come out.

Also to clear this up when re-installing the 03-04 tube when you tap it into place it has a lip it will stop on. You CAN NOT tap it down into the valve cover to far. Removing the tube is also only done on 03-04 D2's. 99-02 = just remove baffle and you are done.

 

Thanks everyone - I've got the parts finally and I'll give it a try in the next few days. I'll be happy to report my experiences. Cheers

 

Here’s what I did today on my 2003 disco
drilled out the little hole for better flow

 

Yep that's exactly what it takes on 03-04 D2's.