YIPPY I'VE GOT IT BACK........
After all that it was the CAT...
It turns out that patern part cats don't work on the 2.2 but they work on the 2.0...
The first thing the garage did when the emissions were high was to buy a patern CAT the same as the one I had fitted last year. The emissions were exactly the same..so even speaking to CAT experts they reconed it wouldn't be the cat with such high HC. Until somebody told them that the GM CAT is a two parter with a pre-cat, aha so upon searching around they found a CAT manufacturer in Nottingham that does type approved CAT's ordered one, fitted it and yep perfect emissions...
So the moral is, if you have a patern CAT fitted ask for type approved and get the emissions tested that way you can be safe.. how many people are buying CAT's that don't work ?