P040200 EGR excessive flow – 2.0 TDI EA288 150hp 2018, cold start

[Djole]

Hi everyone,
I have a VW Passat B8, 2018, 2.0 TDI, 150 hp (Euro 6).
On cold start, once every 3–4 days, the EPC light comes on and the fault code P040200 (EGR excessive flow) is stored. The car goes into limp/safe mode.
If I switch the engine off and start it again, the EPC light disappears and the car drives perfectly normal.

What has already been done:
– Both EGR valves replaced (Pierburg)
– Intake manifold with flap unit replaced
– EGR cooler replaced (original)
– DPF cleaned

Despite all this, the same fault keeps coming back.
The car drives very well and everything feels perfect, except for this issue that only happens during cold morning starts.

Important note:
Before replacing the EGR valves, I also had EPC, but at that time the EGRs were faulty with too LOW airflow. That’s why I replaced them.
After replacement, the fault changed to P040200 = too HIGH airflow.
At this point I really don’t know what else to check.
Has anyone had the same problem and actually fixed it?
Any help or real experience would be greatly appreciated.

Thanks in advance.

 

[mmi]

Please post VCDS Auto-Scan and full engine blockmap files?

A) A set of the files below - when the fault is NOT triggered
B) A set of the files below - when the fault is triggered

1) Full VCDS Auto-Scan​

2) Engine blockmap - Ignition ON/engine OFF - please turn off Stop/Start
3) Engine blockmap - Engine running at idle
4) Engine blockmap - Engine running at idle - 3 minutes after startup
5) Engine blockmap - Hot engine idling - after minimum of 15 minutes of driving​

6) Full VCDS Auto-Scan​

​

How-to create a blockmap file:​

​

[VCDS]​

[Applications]​

[Controller Channel Map]​

- Single Controller Address = 01​

- Login or security access code: Leave blank​

- Function: Measuring values​

- Output: CSV file​

[Go]​

The result (TXT and CSV) files are saved into dircetory C:\Ross-Tech\VCDS\Logs
Please attach the files here.