reinstalling hybrid battery problem. one end 220v and other 0v.

Well, assuming you checked the orange safety plug wires that tell ECU that orange plug is completely in place, I'd think you have a problem with your three relays. But it's weird because those almost never fail and people who replace them later realize it was something else.

Do you have an OBD2 reader and Dr. Prius or mini-VCI and Toyota Techstream to tell us the exact error codes and subcodes?

Make sure you check all the plugs and wires... There's more than 100 connections that have to happen for everything to work again.

 

I think what you're saying here is "the other side" of the relays. Right? Looks like PriusCamper also thought that's what you meant.

Does the green READY appear on the dash? If it doesn't, those relays are supposed to be off, that's what they're there for. The HV ECU doesn't close those relays and go READY until it has checked everything it checks and decided everything is safe to go.

So if the HV ECU thinks there is some reason not to go READY, you'll likely get a head start on your troubleshooting by connecting a Prius-capable scan tool and getting its trouble codes. They will tell you why your HV ECU doesn't think everything's right yet. Note that whatever reasons Parrish21r's ECU didn't want to go ready four years ago in a different car could have been completely different. You should just ask your own HV ECU what it is reacting to in your own case.

 

Sounds like the classic example of "Step 3" not being performed...

 

I think he doesn't even understand thats a relay. if you dont understand that relays function in the grand scheme of things you really shouldn't even be in there but...

probably the orange safety switch is not locked.
You push that plug in the lever flips up...THEN you slide that lever straight down till it clicks. Its now locked and loaded.

There's a little switch that lever engages and tells the ecu at least you have the the safety switch in right.

If it still will not turn that relay on you probably have a ground fault.

Anything the car detects thats funky with that battery the system will not close that relay and allow it to connect to the car till that problem is fixed and code cleared.

Fix the safety switch.. Then disconnect the 12 volt battery that will temporarily clear the code its launched and see if it starts. It will take 2 start attempts. First one will light all the lights on the dash. Shut it off and try again.

if its a ground fault it will come back again..

Oh btw it will not start without the ground strap bracket on either. The starp that goes across the 2 cables that leave the battery

 

Did you install the ground strap I talked about?

 

and bolted the box to the car chassis?

 

When you assembled the battery, did you make this connection? It sometimes gets forgotten about and is the wire for the safety interlock. No connection=no interlock signal. Never hurts to get actual codes tho...