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Yikes, sound like you'e been fairly methodical, a few thought although I'm far from an expert:
You mention the warm-up period being fine and code free, can you hear the exhaust re-circulation flap (or whatever it's called) transitioning from the cold start mode to regular running? Could something in this system be stuck, keeping the car happy when it's cold but angering the ECU gods when things warm up and something doesn't line up?
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