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I think rebuilding yours engine will cose not more then 1.8k pounds. If cylinders are damaged, you can buy kit from kolbenshmidt (not sure that i wrote it correctly) It will cost you maybe 500-600 pounds. it will include 5 pistons, rings, and 5 cylinder liners.

Okey here is getting quite hot now. About 26 Celsium. And car began to start after night from 1 turn. If temp drops below 20 i need 4 secs... if it is about 0 then maybe about 10 seconds.... I really dont understand what happens.

DiscoManMick have you changed ECU as well or only engine?

Or maybe turbo wastegate controller.

Fuel pump :) i think it is dead

Yesterday started engine nearly from 1 crank, but i had full tank.

there were 30 litres:) Anyway i think 1 leaking point i found. Now need to search for another.... possible in the tank where tube connects to pump

So in starting no changes, but engine works better now. Yesterday when i had been removing injectors i found no fuel into them, also there were no fuel into cylinders. So i think there must be a hole somewhere in fuel line.

Okey i changed O-rings and copper rings. On 5 cyl i think copper ring were leaking. because when i removed it, there were air bubles coming from it.

Yeah while engine is cold, my rover is also very loud... especially from 1400-1800 rpms.

Do you see grey or white smoke after start? if yes, then possibly that copper rings are leaking. or 1 injector is leaking. And while car is parked for the night, fuel comes out of it. When you change your fuel filter. What color is it? if its black inside, then somehow that dirty thing comes...

Okey few other ivestigations. Air gets into fuel only when engine is cold. I mean if i start it in the morning, and shuts it down and then wait for 10-15 minutes. Again it will pain to start it. But if it is hot, no problem. It fires from 1 turn. Maybe again change o-rings?

But on TD5 it returns to fuel filter!

But fuel returns after engine not to fuel tank, but to fuel filter. So no air should be.

Same thing here.... the only thing how to check where the air is coming is install clear tube in each part of fuel tubes. i mean after LP pump, After HP pump, after filter. and watch for any air bubbles. I dont know any other ways how to find where the air is comming

Okey lets back to the problem. So far what have i found is that after night air somehow gets into fuel. more of it, if car has only 20 litres or less of fuel, at hot starting i should wait about 15-20 seconds until air is purged. If tank is full i dont need to wait. I see no fuel leaks...

co-incidential i think. Probably oil pump bolt got unscrewed.

Thanks MTurri. So i'll leave it as it is :)

I blanked EGR, but now always get error. It is called EGR has been stucked closed. Can it be fixed somehow? or this is normal?

Yes sorry for my English... any link where i can find info about modification?