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Starting system. Without being there your going to have to chase down the wires and follow the current and see what's getting juice and what's not. But it does sound like its not the starter motor itself. A relay,, solenoid,, broken wire,, fuse,, Ign switch? No way of telling from here.. Sounds...

Sorry I see that now in your original post. Note to self: Read everything twice..lol

Greasyshirt will more then likely respond to ya when he see this..He properly has the best answers out of all of us. I know nothing of the regen systems. Still wondering if the clamps where replaced with new clamps for what it is worth..

First a few questions. You using new hose, new/proper clamps and why did it take 200 miles to warm up?

If your talking about the front grill not being big enought,Im willing to bet the manufacture has the proper opening in it or a bunch of ppl would have picked up on this by now..I would look elsewhere for overheating first. On the blow-by,,if ya cant stop the blow-by attach a long rubber hose...

I would be looking at possible other problems,,,no way should a diesel be affect by 20 degree weather,,,Have ya checked cranking speed,,,thought of possibly injectors leaking down during shutdown,,,wrong weight oil??? Its needs to be colder then He_ _ for a modern engine with clean fuel not to...