D4D 4.2 Turbo Issue?

[RAV4-D4D]

Hi

I have a 4.2 2005, 2L D4D, and a two months  ago I noticed that it was making an odd noise under hard acceleration. It only occurs when the car is a warmed up and the boost according to the OBD is over 12psi.

The sound is a bit like a high speed metal high speed rubbing/rasping noise 

I get no obvious smoke on start up or driving but on a long journey of 200-300miles if use high boost it makes the noise and I can glug through 0.5-1L of oil. If I keep the speed down to around 60mph and lift off whenever it makes the sound (eg when it demands extra boost when going up hills) then it uses no oil. Before this problem came along the car barely used any oil.

• I've tried to check inside the compressor side of the turbo and there's no axial play in shaft, there is maybe a mm or two of longitudinal play. So although it sounded like metal on metal I don't think it is. I've attached a picture in case it helps!
• I've checked the pipes and there are no obvious splits etc so I don't think it's an air leak
• I have no fault codes
• The car drives/boosts like normal (even when it is making the noise), it's just noise and high oil use and I was wondering if the noise is oil mist hitting the compressor blades
• The intercooler has a little oil in it but I took it off today and none came out
• The breather is clear but I can see a light mist of oil in the air intake (hence wondering if high boost in causing oil mist to come through the breather and into the compressor

 

It's an odd problem and open to suggestions/ideas!

Thank you

 

[igormus]

the traces of an oil on suction side is a signal of either bearings wear down or blocking of draining hole\tube from cartridge.

cheers \ Igor