iamdub
Full Access Member
Could do a leak down test too. Pump should hold pressure for a little while after it shuts off. My only concern with it being a regulator is that would show rich instead of lean. Only way to be lean is not enough fuel or too much air. Since it's not feasible to get too much air we have to assume the latter.
On a cold start and in open loop, the PCM isn't monitoring the mixture so it wouldn't report rich or lean. By the time it's in closed loop, the puddled fuel/flooding would be gone and it's running well enough to take in and burn the fuel leaked from the regulator (or elsewhere in the injector spider).
I know he had a lean code, but I was focusing on the other factors he mentioned: burning 1/4 tank of gas during diagnosis (either the mechanics put a lot of miles on it or it's burning a lot of gas), the cats failing (hence their removal), and it acting up just during the first 30 seconds. Those three points sound like it's running very rich which would burn a lot of gas and clog the cats. Also, if running rich enough to damage or clog the cats, the O2 sensors can just as easily get clogged with soot, making them read the exhaust as being lean since it's not "seeing" much of the exhaust any more. The PCM will then try to richen up the mixture, exacerbating the issue.
The discount to this is that it acts up "for the first 30 seconds" before "running fine" after feathering the gas. But, what is the OP considering "running fine"? Does the OP track his fuel mileage? Etc...
***Disclaimer: I must confess that on odd issues such as this, I tend to go far off into left field with my thinking and miss the simpler possibilities.