This one I had was also very intermittent, a couple of other techs looked at it previous to me and the dtcs were always stored not present. When I first checked it out I couldn't fault the APP. I checked connections at the Ecu (near side under front bumper) then jumped the signal(s) with the 5v ref ...
I deal with http://www.blythequipment.co.uk/texa_cars.htm a family run company down south, excellent customer service. I've rung them a few times when I've had problems and there very helpful. He's called Jonah, mention me if you get in touch.
Andy I've only been with Kia for 6 months but I do know they have problems with the items I mentioned. Just checked a few course notes and the egr figures do seem correct. You may have mentioned this before but can you see egr and maf relation when the egr opens? The maf should decrease as you proba...
When the egr was replaced, was the cooler cleaned out? These can block up solid. Are the dpf temp sensors reading ok. As far as I'm aware the egr should be off @ idle but would have to confirm with some of the Kia techs at our dealership.
What car have you got and what's the reason behind loosing the cat? When I had my track car a few years back I just used a O2 simulator.... Did the job