Ad #1) this is strange. Are you sure that the search engine does not find a previous revision of the item? Items/revisions in 'Review' status are excluded from search, even though you may find them (on certain conditions) in the particular folder (this allows performing Reject/Approve directly from Desktop Integration Suite).
Ad #2) this is a known issue. OOTB Reject Reason appears only in the email sent to the contributor/reviewer(s) in the most recent Review/Create New or Review/Edit step.I wrote a simple component that stores is also in the database. You could then modify pages where you want to have this displayed.
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For No.1, I cann't repeat that error again.