cant start car, only ignition mode

Discussion in 'Gen 2 Prius Care, Maintenance and Troubleshooting' started by Andrew_Ph, Sep 19, 2020.

  1. Andrew_Ph

    Andrew_Ph Junior Member

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    I replaced a couple battery cells and put back together and reinstalled. I get 219V on the inside of picture, so it has the power, but not outside, which i suspect is normal for igntion mode. all the wire clips are attached. checked i got all fuses and relays in. maybe i just forgot something since i havent used it in a few weeks?
     

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  2. tvpierce

    tvpierce Senior Member

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    Isn't there a plastic safety plug that needs to be seated properly for power to flow?
     
  3. edthefox5

    edthefox5 Senior Member

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    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.
     
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  4. Andrew_Ph

    Andrew_Ph Junior Member

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    I new someone was going to ask that. Yes it is. And there wouldnt be voltage to the orange wire tabs if it wasnt. I am pretty sure the battery pack/regulator isnt the problem. It just seems strange that this is happening now that i booted up again.
     
  5. ChapmanF

    ChapmanF Senior Member

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    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.
     
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  6. TMR-JWAP

    TMR-JWAP Senior Member

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    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.
     
  7. SFO

    SFO Senior Member

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    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.
     
  8. TMR-JWAP

    TMR-JWAP Senior Member

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  9. Andrew_Ph

    Andrew_Ph Junior Member

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    Ok, I will try that with the disconnect. Yeah, I messed up somehow and posted to gen3 forum, but i will assume for now that they are similar enough.
    I checked codes with torque, nothing wrong, tried resetting.
    5 blue battery bars on LCD. 54% charge, 220 volts.
     
  10. TMR-JWAP

    TMR-JWAP Senior Member

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    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!!

    IMG_7504.JPG IMG_7505.JPG
     
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  11. Andrew_Ph

    Andrew_Ph Junior Member

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    these martian connector things always drive me nuts.
    Turns out the orange disconnect comes in 2 pieces and it fell apart in the process. when i put it together that small connector that i didnt know about was upside down. well, thanks for the tip.
     
  12. ASRDogman

    ASRDogman Senior Member

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