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In addition to performance target, recent stringent emission legislation and reduction in oil consumption are the major driving force for engine design and development. In this reference importance of crankcase ventilation has increased immensely and the manufacturers are bound to develop most efficient system with high oil trap efficiency. In crankcase ventilation system, the blow-by gases from the crankcase are routed to the intake manifold through Oil separator system. The oil separator task is to retain the oil part from the blow by gas and send it back to sump. Developing an oil separator for the engine studied here was very challenging considering double stage turbocharger which produces very fine mist of oil and is difficult to separate. The study shows that oil mist coming in blow by is of size 0.3 micron and lesser than it. The major contribution of these fine mists was from turbocharger.