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What you're describing sounds like the engine doesn't combust properly at first.
When the engine has cooled down completely overnight, the system injects more fuel to compensate for the diesel that is deposited on the cylinder walls within the first few seconds.
However, there are always times when the EGR valve jams or does not close properly. Then additional air enters the cylinder, which disturbs the combustion. This can lead to a so-called knocking combustion which explains the noise and also the smoke.
The workshop should close the pipe of the EGR valve with a sheet metal. The next day you try to start normally. If the problem does not occur then the EGR valve is the cause.
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