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It can only be 1 of 2 things - either your fuel pressure is outside proper limits - blocked fuel filter/ pipework or you have a sensor fault.

I have also checked the world-wide ££££££ on google -...

This is the 'electronic' plastic key yes???

It sounds like a trip to the dealer, sorry!

Aw well if you know the guy I'm sure his advice will be good.

If your Cat is duff - they are significantly expensive why not invest in a 3" downpipe and sports cat, and a cheeky wee remap to go...

How about a custom made stainless steel?

£300 to £400 and you can specify the muffle size etc.... Will do wonders for your sound too:

http://www.youtube.com/watch?v=pGvPtZRN-2U

That's a BSR...