Not convinced that you can expect normal performance with NO exhaust system downstream of the exhaust manifold. Where will the fuel trims go with the O2 sensors hanging in ambient air? I just came though my problem , it was in fact a partially clogged cat. Car was running as bad as you described yours does. Mine runs like a raped ape now! The odd thing about my case was that I never did get any cat converter codes like the typical P0420 low cat efficiency code, as things got really bad I was on occasion tripping the P0404 EGR performance error code , which from what I have read, is commonly tripped by excessive backpressure from a clogged cat which causes the EGR valve to pop out of the shut position. Another symptom I had was rich exhaust smell getting into the car from the ventilation blower sucking in fumes from the engine bay that were pissing past the exhaust manifold seals on the head exhaust ports due to the excessive backpressure.
You said you were seeing 3 psi of exhaust backpressure. Was that measured at the upstream O2 sensor exhaust port? At normal idle, or a high speed idle? Seems pretty high, shouldn't see any significant pressure at that point at normal low idle. What do your fuel trims look like with the cat installed under load going up a long upgrade? If the cat is clogged you will likely see a bias toward lean (negative number) trim due to a rich mixture. If you are fuel starved ( like if your fuel pump is on its way out) , you would be seeing a bias toward rich trim. I'm mentioning that because my fuel pump actually just died the other day, but I dont think it was related to the clogged cat condition. That said, even with my 3.1's lousy performance with the partially clogged cat, the lean trim bias I was seeing under load was not that gross. But it was there. Another thing I was seeing from the clogged cat was a lot of coolant temp rise under load during uphill pulls, never had that under normal operation and that is now gone with the new cat.
Clogged cats on these cars we enough of a problem that GM extended the warranty on the cats for clogging to 120k miles/10 years. Mine only had 95K but was 13 years old so I was SOL for a warranty replacement from GM. The Walker cat my mechanic put on was about 250 bucks over the counter and I have seem them for about 180 at the usual Internet parts outlets.
Well, since the car has been sitting over a year now, i cant tell you exactly what all the fuel trims were reading. Having it hooked up to my scanner, the only code it ever threw was a P0403. All the other readings at the time from what i could tell were in acceptible range. TPS swepped fine 4.5-5 volt WOT... temp sensors seems fine, nothing really out of the ordinary. Back pressure from the exhaust was measured from the down stream O2sensor
at idle and under a load, even with the exhaust completely unbolted it acted no different then when it was hooked up, reguardless of what the ambeint reading where giving it.
I work in the automotive industry, in a small , but very busy Tranmission shop. I mostly install but do some building... still learning. BUT every other shop I have talked to says they would have done and checked all the same things I have already done. So , I pretty much ready to start from scratch all over on it with some fresh prespective. Obviously , it is something simple I am just over looking.
To be honest, the Cat conv. the only thing I have not changed. Things i have changed ...EGR, MAF, ICM, Fuel pump, Complete intake manifold gasket set, ( someone mentioned, may have internal intake leak...idk, but i changed alot in the past for coolant leaks. couldnt hurt), new muffler and even changed pcm and re-flashed by dealer. recent tune-up plugs and wires, even swapped coil packs, no diff.
Anyways, i will try to get back on it this weekend with my Solus scanner and I can let you know what the O2's are reading, but if I remember correctly, think all the O2's were doin thier job.
Thanks, this is the most in-put i have got back on thins car in months, lol , much appreciated