Fixed this one at last!Firstly to thank & answer you guys.
Mike
I didnt try swapping the catalyst itself. I sprayed generous amounts of carb cleaner around the (HOT ) exhaust manifold, Sensor mount boss & flanges. I didn't observe any response in the O2 sensor signal, so I felt happy that there wasn't an issue with cracks.
Darren
I did isolate the original wiring to the O2 sensor when I rewired it, although I didn't go to the trouble of shielding it. Do you think that will create a problem? (obviously this is done for a reason). I didn't notice the scanner reading with the O2 sensor disconected, but I did measure the voltage at the earth & signal wires. I found 200mv & 450mv respectively (from memory & need to confirm with my notes). These were the same on both bad & doner vehicles.
I thought long & hard about the oil change, but you know what it's like with these car traders, they wont want to pay for the hours I have put in, let alone any unnecessary extras. I tried hard to determine whether or not the oil factor was an issue, by monitoring the emissions whilst removing the oil filler cap, the breather pipes etc & as I saw no effect on HC's or O2 sensor response, I felt happy that the oil was not a problem.
Lee
Yes, if I put a simulated lean voltage down the signal wire, it would drive the emissions down, as it did when I put a reduced voltage down the MAF signal wire.
Now the fix!
Unfortunately I decided as a very last resort to try yet another O2 sensor, this time off the donor car, instead of another universal 4 wire. Straight away I could see a nice full range switch on screen & the emissions came into range within a couple of minutes of idling, without any need for extreme preconditioning.
What a disappointing end to an interesting problem hey! The fact remains that the voltage taken from the O2 sensor was still different from that seen at the scan-tool by some 250mv. This was confirmed on two tools. This anomoly was not evident on the donor vehicle & I must admit that I had been driven off the scent with my determination to explain this.
Anyways fellas, a result is a result I suppose.
Thanks for the input & thanks for reading!
Have a good weekend
Dave (Hill)