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Yep Valve Cover side depends on the year or the valve cover installed. Normally 99-02 had it just exposed for the most part in a tube and you can either pull up gently to remove it with needle nose or drill a hole thru it, and install a wood screw and then pull up. On 03-04 you have to remove the nipple from the valve cover (it's pressed into place) and normally with some carb spray, and a rag wrapped around the twist & pull up method works. Then you remove the baffle, drill out the hole in the nipple to 5/16 to 3/8 and then re-install (you want decent airflow thru it). Or cut the end off completely by a few mm to be the same as the 99-02 setup.
Did this today on my 04 D2. Thanks Best4x4!
Only thing is, I did not thread the PCV all the way in. Its looks to be tapered so I only had the bawls to screw it in a bit over half way. Its nice and snug though. Took it for a long drive this afternoon and everything checked out fine with the mod. My old oil seperator was completely clogged and I had to drill into it several times, then break it and take it out in pieces.
Any good practice for removing the broken plastic valve from the manifold? I was working on something else yesterday lying on top of the engine and snapped it right off. I tried to use an extractor but it is stuck in there, almost like it is glued.
I'm in the same boat, screwdriver didn't work, just hollowed it out more. Super stuck in there, so currently I have a big extractor bit threaded into it and the FV308 in the end of the hose not connected... first time in a while I've had no vacuum leak though...
I'm thinking I could just keep turning the extractor and it might start unthreading the plastic but didn't want to risk galling the threads on the aluminum intake manifold.
Might have to get some dental tools and start picking the plastic out in bits.
I could get mine out by turning the nipple with a pair of pliers (not from the side, but by sticking one side into the hole and wiggling), since it was still sticking out a bit and not completely broken off. If that doesn't work, maybe penetrating oil, heat or solvents can loosen the plastic nipple.
With such a heat gun with a small nozzle you could try to heat up the plastics from inside the nipple, which would be more effective than to heat up the manifold from outside. I placed a 1/4 NPT for comparison. The heat gun is used for electronics soldering and reaches temperatures above 400F:
Last edited by Discorama; Feb 5, 2019 at 02:10 PM.
