1.6 TD crankcase ventilation

[Ohiobenz]

As I'm wrapping up putting the engine in my Samurai back together I'd like to set up the crank case ventilation a little better than what it was like when I bought this rig - a loose hose dangling in front of the intake.

The BOV is eliminated, Air intake is via K&N style cone filter.
I still have the original 1.6TD valve cover breather, which has 2 ports - a larger and a smaller one, there is a fitting coming out of the crank case, it is running a Corrado valve cover.

If I want to avoid a catch can, what is the best way to plumb this?
Should I add a fitting to the intake tubing post intercooler?
Does the smaller port on the breather go to the crank case fitting?

Thanks!

[ORCoaster]

I would say that you can use that breather.  My setup has the lower crankcase hose going to a tee that joins a hose that feeds in after the airfilter but before the turbo.   

The routing you propose seems reasonable if I am envisioning it correctly. 

[Ohiobenz]

Thanks

What about the 2 outlets on the valve cover breather?

[77highboy77]

You don't want to tee into the intake tract after the turbo, if you do you'll be pressurizing the crankcase under boost. You'll want to tee in just before the turbo so there's no boost pressure. You can tee it in after the turbo, but you'll need to add a checkvalve to keep the boost pressure out of the crankcase. This method will block off ventalation whenever you're under boost though.

[Ohiobenz]

Right.... I wasn't thinking straight there.  Didn't want to run any oily vapors through the intercooler, so I guess a catch can will be the answer :-(

[Ohiobenz]

https://images.app.goo.gl/JZK4NwUHBewUoyGL8

Looking at this solution.

[ORCoaster]

I can see running a catch can if you want to have the air sucked up into the front end of the turbo.  You would have cleaner air entering the system and keep it out of the intercooler.  But if you tee into the air being sent to the intake after the intercooler you wouldn't need to clean it. It would be burned in the engine. 
Do the two ports on the valve cover breather connect and allow air to flow out one of them.  I am thinking that there is one air entry coming in from the valve cover and then one of the two ports on the breather can be used for the lower hose from the crankcase.  Then the remaining port gets a hose that goes post intercooler or on the intake. 

Does that work for you?

[fatmobile]

 I run a hose from the port on the front of the block
up to a 3-port vw gassser, 2.0, ABA, PCV puck that sits on top of the valve cover like the 2-port TD puck.

[Ohiobenz]

Fatmobile, where does the large hose from the PVC go to when there's no intake box?

[Ohiobenz]

ORcoaster, any air post turbo is pressurized and would  not work for scavenging the crank case.

I'm not sure where I have room to mount the catch can....

[ORCoaster]

Absolutely Correct!  Where did my brain go on that one?  The only choice for scavenging oil is at the front end of the system then. 

Any room to mount a can on the front fender areas?  Maybe a small diameter can be between the air filter and passenger strut? 

[Ohiobenz]

This engine is in a Suzuki Samurai...
How do I post pics off my phone?

[ORCoaster]

Save the pics to a third-party service like Dropbox and then insert them from there using the icon under the bold icon on this page. 

No way to just post photos from your phone directly. 
at least not that I know of.

[fatmobile]

 PCV goes between the filter and turbo.

[ORCoaster]

But not as I tried to explain it;  Pre turbo not post with the boost on it.  Must have been all the nog for the day that did me in on that.