prius will not start after hybrid battery change

2 things to do real quick. Unplug the 12 volt aux battery in the trunk. Thats easy just take the yellow dust cover off the pos terminal assy and then where the big black lead conmes in to that assy its on a click connector. Just unclick it and pull it out. That will remove all dtc's and essentialy reboot all start up ecm's. Plug it back in and put yellow cover back on.

And the other which seems to get everyone is the big orange battery power interlock connectior. The one you call the safeplug. It has to be slid and locked closed. Double check that make sure its seated and locked.

 

Not sure how your seeing 216 which is pretty close to Hybrid total cause that conector should be dry until the High Voltage relays close in that battery box. Unless your saying you put it in Ready and you do have 216 there.
If so thats not good. That means the Hybrid battery is charged and the relays are closing correctly but the Inverter is not turning on. Inverter failure. You didnt reverse polarity the 12 volt battery anywhere did you by mistake?? Jumping it maybe? Time to check all the fuses in the car.

But worth it to check that safety plug. I have never touched that plug but many people here have so I'll let them explain how it works. There's a part that slides it closed and then locks.

In the meantime best way out of this is to harvest the Hybrid codes its throwing. We need those trouble codes complete. That will tell where the car is unhappy now.

 

The system main relays are located within the traction battery case. The purpose of those relays is to open the high voltage circuit when the Prius is IG-OFF.

The inverter is located in the engine compartment and is the object covered by a large square shiny aluminum cover. If there was an open circuit, apparently someone removed or loosened some of the high voltage wiring leading either to the traction battery or to one of the two MGs?

 

That makes sense as you should not see 216+ at that big orange safety connector unless the car is in READY. Somehow the relays in the battery case are stuck closed. Never heard of that. Extremely dangerous. Your very lucky it didn't bite you. That may have damaged the Inverter hot plugging it in.
But pay atttention to what happens from here on out. Do not approve anything the dealer lays on you till you post it here. Your in a very bad spot having to rely on the dealer now.