You might notice that Rover 2 in my signature block is Mike's (OP) Rover in this thread. My wife and I met him, he is a really nice guy, and bought the Rover and we have been giving it all the TLC it needs. While the guides were not broken as they had been replaced sometime during the car's history, there were pieces of guide scattered throughout the lower part of the engine and the previous tech that changed them used way too much RTV which amazingly did not clog the oil pickup tube or get in any of the oil passages. While the guides had life left in them, the engine did need to be taken apart to address other issues, so we ripped the entire front end apart and just replaced everything. The issue was a seized alternator bearing and completely seized primary and secondary belt tensioners. There was also a broken PCV oil drain hose and serious oil leaks. The Bank 1 Vanos non-return valve was stuck, and the B1 Vanos transmission had a cracked plastic ring and was spurting oil through the front. The timing chain tensioner was the old style and not proving sufficient tension either. The A/C compressor had zero oil left in the system. We also swapped the steering wheel and airbag for good units, the steering wheel got the silver inserts and heated functionality, and we repainted some of the interior foundry finish to gloss black. We also lubricated the internal HVAC fan and changed the fascia to gloss black. The transfer case motor was rebuilt too and is working now. We're very proud of our result as DIYers and we spared no expense and scrutinized every detail.
I'm posting this to serve as an inspiration to others that you too can save a Rover. Maybe I'll start a non-profit called Save The Rovers, because I have a weakness in my heart for these cars, especially the early model L322s and 2004 is my favorite year. Very few shops would put the detail into this like we did, with replacing every fastener, stripping and properly painting engine parts and pulleys and customizing specific hoses for ease of future service. We reckon all the work and custom approach would probably have cost $10k from a shop, yet we spent about $3k in parts.
Here's some pics of the rebuild. We replaced every gasket and seal (except head gasket), flushed/backflushed fuel injectors and replaced filters and seals, replaced all hoses and vacuum hoses, replaced ALL engine accessories, replaced all A/C seals and desicant, vacuumed and refilled, did the full timing chain and tensioner replacement with new Genuine BMW parts, painted upper timing case covers and valve covers, all new spark plugs and ignition coils, extensive cleaning and tons more. We used the German Auto Solutions timing kit which was awesome. We also replaced many standard torx fasteners with yellow chromate zinc-plated hex bolts of the same if not better tensile strength, used silicone vacuum hoses to replace nearly everything, and replace all other major hoses in the car. We redid every A/C seal and other gasket. The car runs and every major feature works. We also did the valley pan, rear coolant crossover pipe gaskets (we also modified the rear coolant crossover pipe with the BMW drain plugs and gaskets by threading holes in the ports, for possible future use), and installed a German Auto Solutions lower pressuer coolant cap. The power steering pump, hose and reservoir were changed along with the coolant reservoir and water pump.
We're only working through one problem with the Vanos shutting down during idle due to a P0011 and P0012 code, which we assess is due simply to upper timing covers not being seated down all the way. We have double and triple checked the timing and it's spot on. Waiting on the BMW tool to seat those down properly and we'll be putting new impulse wheels in and retiming it again. At 2,000rpm the engine is buttery smooth. Should be daily driveable soon and then my wife and I plan on doing a 2,000 mile trip to GA and SC in August. Later this year we plan on going to Assateague Island for a weekend trip with another friend of ours who has a 2012 L322 Autobiography. Lots of life left in this Rover.