As far as I know, the attaching of the files (content.html etc) cannot be avoided if the formatof the inbound email is not plain text.
But if the opening error only happens via the web console and via the full client then it would seem to me that it must be an issue between the PC where the browser is running and the web console server.
Does it happen if you use a web browser on the actual machine which is running the web service?
Do think i might have cracked the problem. I have noticed that all my (content1.html) is kept in my c:\windows\temp folder.
I have received a answer from HP that i need a patch to get rid of that problem permanently.But in the meantime, i need to stop my services running, and purge my cache and delete the contents in the temp folder.
Thank you for all your help. Seems like this issue is resolved.