I have the valve covers off and figured I'd replace the oil separator while I was in there. The '04 model has a metal chamber that the separator fits into, but I'm having trouble getting it out. I've sprayed penetrating oil and carb cleaner in there, and the old one is loose – it moves up and down in the chamber a bit – but won't come out. There's a guide here (https://landroverforums.com/forum/di...t-22897/page4/) that suggests you should punch it out from above. I've tried doing this, but there seems to be a lip of some sort that's preventing it from dropping out the bottom. I'd rather not hammer on this hard and break it up inside if I don't have to. Any ideas?

 

Did this recently on my '02. It will not come out of the bottom. Needs to come out of the top. Unless I am mistaken and the '04 is different.

Small needle nose pliers, and work it out. Lol... Probably one of the more annoying things I've done to my D2.

 

Sadly the '03-'04 models are indeed different. They have the separator in a metal cartridge with a pinhole at the top that is permanently affixed to the valve cover.

 

You can pull tube off of valve cover if you want, or just leave it on & tap the seperator out of tube, using right size metal piece that is a little smaller than tube itself or a long screw (whatever fits in tube nicely) & hammer it out gently,,
If you never want to worry about it or mess with it again, then do what I did, after I read a forum member suggestion,,,,
Just leave the plastic piece out, & buy a fram FV237 PCV valve for $3-4, or a similar purelator part, & connect between existing metal tube & intake connection using same hose that you have (or a new one) ,, I did this a while back, after reading it in a tread, it's a very good mod, new pcv valve actually has a valve inside, so it won't get clogged easily, & cleaning it if necessary is very easy,,

 

Well, I got the old separator out of there. I tapped it out with a 2.5mm allen wrench, destroying it in the process. I'm petrified of putting the new one in now - it just barely will squeeze in there and is a fragile piece of plastic. I'm thinking about filing it down on the sides a little so it's not such a tight fit. Anyone have any tips on this? Lube it up heavily?

 

Do the mod as mentioned above. It makes servicing the system simple.

If you insist on using the one you have, use a properly sized socket to push it in that way the nipple is not damaged. Also lube with oil.

 

Great suggestion, thanks. I have a new separator, so I figure I'll at least give it a shot before trying a different route.

 

Just an update for anyone who might look at this in the future: I got the new separator into the metal cartridge using a socket, as suggested, after lubing up both parts. It was a very tight fit, but it got in there undamaged. I blew through the pipe a bit to make sure air could pass. While replacing the setup with a fram valve would be more serviceable, I'm calling this a success.

 

Never would have thought that. Good to know.