Help with Insulation Test and DTC Codes

you found the core of the problem. following the manual you would get a false pass which is what wadtp and I found, so step 16 should also incorporate one additional step at testing the framewire the way Wardtp and I have done. see pictures on post #5 and 29. I speculate that the problem might be with the wire internal insulation deterioration overtime and starting to make a contact with the shield wire, perhaps hits underneath the car with road hazards since the wire is partially exposed on the base of the car (just a plastic jacket covers the wires). like I said I am planning to dissect the wire at one point to find the source of the problem, I'll report back in a few weeks.

if you read post 28 and 29. I made an attempt to explain the problem and I also provide pictures of the testing.

 

I tagged @Wardtp on the post, and am still waiting for more detail on exactly what was done, not by you, but by Wardtp in the early posts in this thread.

The core issue could end up being whether a person interprets "disconnect all the HV terminals of the SMR" in step 15 as also meaning to disconnect the frame wire shields at that time. It's possible a person might assume that, or just find it physically easier to undo the cable there as well, and it's true the manual doesn't explicitly say not to.



Edit: taking another look at the kicking-around-the-web 2006 manual, there is an illustration for step 15 that does show the frame wire disconnected not just at the SMR terminals but also at the shielding. That's probably the real mistake: if you do that in step 15, and then in step 16 you unplug the front end of the frame wire from the inverter, you end up taking a megger reading between body ground and the frame wire whose shield is no longer touching body ground at either end. If step 15 only disconnected the SMR terminals but left the shield grounded, the test in step 16 would work fine.

That doesn't seem to be the only thing wrong with step 15 (or the identical step 6, with the identical illustration), either. I'll open another thread on that.

 

Glad you found the answers to your own questions. And btw wardtp and I had the same exact issue.

It's evident that the manual needs revisions and it was not carefully written. I wonder if the new version corrected this errors...

A new good thread would be on all the "2006 manual revisions". Assuming there is no one already. That would be one useful thread.

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