How are these voltages?

Your mechanic says 16.91v vs 17.03v is a big delta?
Seems odd.
Maybe get the Dr Prius and a good OBD2 reader yourself and do some diagnostics.

Also GreenBean refurbished batteries are crap.
GreenTec batteries with new cells are better
OEM is best,

 

The voltages you're reporting are not useful for diagnosing your problem because the car was in READY and charging the battery while you were measuring them. It's like trying to determine how much water is evaporating from a cup while you're filling it from a faucet. If you need to go by voltage readings, your best option is to let the car sit unused overnight and then check the voltages. Hopefully, by then, the charge voltage will have dissipated and you will have a more accurate indication of which block is the weak link. Each block is comprised of two modules and each module is comprised of six individual cells inside the plastic housing. Typically, when a module fails, one of the internal cells has gone bad and the module voltage will drop to about 1.3 volts lower than the others.

Before I forget, if you do the morning voltage check, make sure you keep your foot off the brake and press the power button 2x to put the car in IG-ON mode. In this mode, you will have full access to the OBD and ecu information, but the car will not close the main HV battery relays, so the inverter will not power up and the engine will not start. This will prevent and "charge" attempt being made.

The P0A80 code will trigger when the car determines there's a problem, but it will also allow you to continue driving normally. If it's a module causing the problem, the car will eventually determine the weak block and will trigger an additional code to ID that block (like a P3014) and the car will go to limp mode. Depending on the software your local mech has, he may be able to look at freeze frame data to see which module was lowest at the time the P0A80 was triggered, but it may not be 100% truthful.

 

"Torque Pro" will allow you to monitor the 14 pairs of modules in real time. The pic shows my pack during a full throttle acceleration, from a dead stop. Note that 146 amps were being drawn from the pack. Module # 28 was weaker than all the rest, and was replaced after this data was collected.

 

I have had a Gen II Prius since 2007 and have recycled the battery myself 3 times. I don't believe those battery readings are out of line are far as the spread. The spec on the battery is 201 volt, but I have seen a fully charged battery read between 230 and 240 volts regularly. Your battery is 237.74, which is in the proper range.

 

Sorry, but you're not going to have 17 volts on a block unless the car is in ready mode or was just very recently taken out of ready mode where it was under a charge condition. Same reasoning applies. The problem is being hidden.

 

Torque Pro will need prius specific files added to the app in order to read battery voltages (there are threads in the forums about this).

FYI, if you have access to an "OE level" scan tool, then the P0A80 code should have freeze frame data attached to it that will give info about the ecu saw when it set the code - such as bloch voltages.

Another test you can do is to put the car in ready and turn the A/C on (hi fan & full Low temp) while watching block voltages on Dr Prius. Let the car sit - the ICE should stay off until the State Of Charge drops to around 45%. During this test see if the Voltage Difference data gets above 0.5V and which block goes lowest.

You can also (have someone else) watch voltages on Dr Prius while you drive the car hard. Sometimes a weak module will show up during heavy discharge on acceleration.

Posted via the PriusChat mobile app.

 

Yep.
Their prices have increased a few hundred dollars lately but still cheaper than Toyota on an installed basis. If it were me I’d go route of Toyota as OEM battery is trouble free and will outlast the remaining life of the car but some people who have smaller budgets or shorter timelines may opt for GreenTec. I bought one of the GreenTec batteries for a Camry hybrid years ago and it’s still going strong. I’d rather not learn how to DIY replace a battery since I’ll never use that skill again. Life is too short.
Many here will have other opinions but my comments are based on personal experience not hypothesis.

 

Those numbers don't look like a cause for concern.

You will need to do some load testing or use the Dr. Prius test to see what might be the cause of the P0A80.