P0401 - EGR System - Insufficient Flow - Intermittent

I just rolled over 205,000 miles on my 2009 Jetta TDI. I have no mods installed. About two weeks ago the check engine light came on. Ran VCDS and it showed 3 faults:
1. EGR System - P0401 - 000 - Insufficient Flow - Intermittent
2. Exhaust Re-Treatment Post-Injection - P20D8 - 000 - Control Limit Reached - Intermittent - MIL ON
3. 009235 - Exhaust Gas Recirculation System - P2413 - 000 - Performance Malfunction - MIL ON

I then took off the throttle body and EGR Valve, cleaned thoroughly, and reassembled. Ran VCDS again and cleared codes. The check engine light was still on. The next day the check engine light was off. For two days the check engine light was off. Then on the third day it came back on. I ran VCDS again and it has the same 3 faults.

Where should I go from here?

Mileage: 330370km-205282mi Repair Order:


Chassis Type: 1K (1K0)
Scan: 01 02 03 08 09 0F 15 16 17 19 1C 25 42 44 46 47 52 56 62 65
72

VIN: 3VWCL71K69M001545 Mileage: 330370km-205282miles

01-Engine -- Status: Malfunction 0010
02-Auto Trans -- Status: OK 0000
03-ABS Brakes -- Status: OK 0000
04-Steering Angle -- Status: OK 0000
08-Auto HVAC -- Status: OK 0000
09-Cent. Elect. -- Status: OK 0000
0F-Digital Radio -- Status: Malfunction 0010
15-Airbags -- Status: OK 0000
16-Steering wheel -- Status: OK 0000
17-Instruments -- Status: OK 0000
19-CAN Gateway -- Status: OK 0000
1C-Position Sensing -- Status: OK 0000
25-Immobilizer -- Status: OK 0000
42-Door Elect, Driver -- Status: OK 0000
44-Steering Assist -- Status: OK 0000
46-Central Conv. -- Status: OK 0000
47-Sound System -- Status: OK 0000
52-Door Elect, Pass. -- Status: OK 0000
56-Radio -- Status: Malfunction 0010
62-Door, Rear Left -- Status: OK 0000
65-Tire Pressure -- Status: OK 0000
72-Door, Rear Right -- Status: OK 0000

-------------------------------------------------------------------------------
Address 01: Engine (CBE) Labels: 03L-906-022-CBE.clb
Part No SW: 03L 997 016 P HW: 03L 906 022 J
Component: R4 2,0L EDC G000AG 8681
Revision: --H01--- Serial number: VWX7Z0H324L06J
Coding: 0050078
Shop #: WSC 34328 002 1048576
VCID: 3F8ADBD36E6E1BD9561-806A

3 Faults Found:
001025 - EGR System
P0401 - 000 - Insufficient Flow - Intermittent
Freeze Frame:
Fault Status: 00100000
Fault Priority: 2
Fault Frequency: 71
Reset counter: 255
Mileage: 327707 km
Time Indication: 0
Date: 2000.00.00
Time: 09:08:57

Freeze Frame:
RPM: 1748 /min
Speed: 14.0 km/h
Voltage: 14.14 V
Load: 80.0 %
Load: 100.0 %
Mass Air / Rev.: 270.0 mg/str
Mass Air / Rev.: 410.0 mg/str

008408 - Exhaust Re-Treatment Post-Injection
P20D8 - 000 - Control Limit Reached - Intermittent - MIL ON
Freeze Frame:
Fault Status: 10100000
Fault Priority: 2
Fault Frequency: 5
Reset counter: 255
Mileage: 327681 km
Time Indication: 0
Date: 2000.00.00
Time: 18:48:48

Freeze Frame:
RPM: 1679 /min
Speed: 70.0 km/h
Torque: 102.0 Nm
(no units): 0.80
(no units): 0.90
Temperature: 294.0°C
Load: 19.6 %

009235 - Exhaust Gas Recirculation System
P2413 - 000 - Performance Malfunction - MIL ON
Freeze Frame:
Fault Status: 11100000
Fault Priority: 2
Fault Frequency: 2
Reset counter: 255
Mileage: 328009 km
Time Indication: 0

Freeze Frame:
RPM: 0 /min
Speed: 0.0 km/h
Load: 0.0 %
Voltage: 12.16 V
Torque: 0.0 Nm
Temperature: 70.2°C
Bin. Bits: 00000000

Readiness: 1 3 0 0 0

hopefully we will hear the details of the "fix" in the near future, which should, for a 2009, include a new DPF as well as different NOX cat and low pressure egr filter.

these would take care of your issues.

in the mean time, there is likely no long term impact from driving it the way it is.

(other than some higher emissions levels....)

have you registered with VW for the "fix" on your car?

I have registered for the "fix".

Been reading about DPF on another forum and the replacement doesn't sound like it will be fun for a DIYer.

I should also add that since the CEL came on I am hearing a sound during acceleration like air being released from a tire.

you should look close for a boost leak, or other leak, (perhaps in the high pressure EGR)

Look closely where you took off and replaced the parts.

might want to check the soot levels in advance measuring blocks, (with the car running)

and log some boost values, commanded vs measured...


and run a Basic settings 078 to verify that the low pressure EGR filter is the cause of the P0401.

See discussion >
TDIClub Forums > VW TDI Discussion Areas > TDI (Diesel) Emissions
"Managing a sooty tailpipe" item -

Leave the fault there - unless it would prevent passing a smog or vehicle inspection check.