No i didnt do any testing before i started as it was an old wylex fuse box all the wires were short and twisted together so i thought id do it when i had finished.
My question is, where do i stand with the paperwork if the customer doesnt want to pay to get it fixed.
I did explain before i started that installing a new CU can flag up problems.
You can do an IR between lives and to earth from the busbar, no need to undo any connections.
if you explained that it can flag up problems and wrote it in your quote, i do not see the issue. You told them, there is a problem, it needs sorting.
If he won't pay it iooks like its your loss on this one. The fault needs clearing to connect to the RCD, and certify or you have just installed a white elephant in place of their wylex unit!