DJ:

Your injection timing is too fast -- you really need to set it with a drip tube or substitute, it's not gonna run much better way to fast that it did too late, and you can burn the prechambers.

Some noise is normal cold -- even my 603 clatters a little, but is should subside pretty quickly and essentially disappear as the engine warms up some. Fast timing will also give you rough idle.

I'd also plan on the timing chain replacement -- they DO eventually wear to the point they fail, and that's expensive, plus you still have late valve timing, reducing low end power and making more smoke than you should.

Peter

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1972 220D ?? miles
1988 300E 200,012
1987 300D Turbo killed 9/25/07, 275,000 miles
1985 Volvo 740 GLE Turobodiesel 218,000
1972 280 SE 4.5 165, 000 - It runs!