cant start car, only ignition mode

Isn't there a plastic safety plug that needs to be seated properly for power to flow?

 

The orange safety switch on the side of the hybrid battery may not be latched.

When you plug it in then you must push down on the top edge to slide it down and lock it. There is a small switch that plug engages that tells the ecu the the plug is installed but it must be down to engage the switch.

 

I'm not saying yours isn't correctly seated, but just for the information of future readers, this one claim above does not reflect how it works.

There are two things going on in that safety plug. One is a fuse and a set of blades that physically interrupt the high-voltage circuit. If you have the plug pulled out, yes, the battery circuit will be interrupted and you won't see battery voltage across those tabs on the battery side of the relays.

The other thing going on in that same safety plug is a low-voltage interlock switch, closed only when the handle is all the way down and slid home. That switch does not interrupt the high-voltage circuit at all; it is purely a low-voltage signal to the ECU that it will be safe to allow the car to go READY.

If that switch is not made, the car will go to ignition mode but not to READY (and a code will be set saying that's the reason). That will not affect the battery voltage you can measure at the relays; as long as the plug is not physically removed, that voltage will be there.

 

Another possibility is the low voltage safety contacts aren't plugged in. There are three plugs that connect to the HV battery. The smallest one plugs in just above the safety disconnect. The other side of that plug goes to the bottom of the safety disconnect to the interlock contacts. Many times, this end of the cable gets forgotten about during reassembly. If it's not plugged in, the car thinks the safety disconnect isn't installed.

 

Those images are from a gen2 hv battery, but you've posted this thread in a gen3 forum.

If you could please post/share any obd2 codes (DTCs) that would be helpful as well.

 

Looking more closely at the photos, I'm going with the handle is not pushed down to satisfy the interlock....take a quick look at the below link. It has a picture of what we're talking about. Step 3.

New replacement battery - started great, tested 80%, now won’t start at all | PriusChat

 

Look at your photo that shows the disconnect. Note how similar it looks to my top photo. Then look at the bottom photo and note the much larger gap between the top tab and the slotted area of the handled. Guess which one has the switch lever pushed downward to engage the interlock contacts? At least this is an easy fix!!

 

So did you get it running???? What that the problem?