Any further ideas?
You won't thank me for this Jaime.. but....
Get an exhaust sniffer in the header tank.
At least that way you'll have a much better idea it's not a head gasket issue. I know you don't suspect HG, but, it's not unheard of, and exhaust in the coolant will cause over pressurising and bubbles...
At least that way can eliminate it
If it does turn out to be HG, it won't be a fun or quick job (certainly not a day, like the rover!) .. I've never done a HG on a TD.. but I'm pretty confident that between you me and Tunnie, we could have a crack at one
Whilst I won't go as far to bet bodily parts, I will say it ain't the HG. For a moment yesterday, I did wonder, but I am convinced not. My reasoning:
It runs too well (except for missing a bit on startup, thats a different issue that I know about).
Diesels run at double the compression ratio of petrols, so HG failure allowing cylinder/coolant contamination would result in poor running (remember, diesels rely on compression to ignite fuel), using lots of coolant (only coolant I lose is what it blows out of the top), and diesel fuel/exhaust in coolant (which given the nature of the fuel and exhaust gases I would say would be visible).
My bubbles seem to appear during the bleed stage after refilling, or once/after it is very hot (I suspect the coolant is boiling somewhere).