Replaced traction battery, now engine wont start.

Find the orange traction battery interlock switch on the left side of the traction battery case. When you reinsert it into its socket, you must first pivot the lever 90 degrees. Then you must slide the lever to lock it in place. The second part of that process often is omitted, causing warning lights and preventing the car from running.

 

Well, if you are sure that the orange interlock switch is correctly inserted, then maybe the next step is to open up the traction battery case again and inspect the wiring harness connectors leading to the traction battery ECU.

What about the system main relays, didn't you have to move those over from the old to the new battery case?

I assume that the new battery came with the orange plastic bus bars and the very thin-gauge voltage sense wiring. Make sure that wiring was not damaged.

 

I'm still betting it is the interlock switch not properly inserted. I have seen this too many times and it always turns out to be the interlock switch not inserted properly.

Here's one example
Help! Oh no! No Ready Light after replacing Traction battery | PriusChat

Here's another
transaxle disengaging & hybrid system & ABS warning lights | Page 3 | PriusChat

And another

Hi Patrick,​

Thank You! You got me thinking about the 'full' operational positions of reinstalling the Traction Battery Service Plug.​

I thought the two small pins on the Service Plug "engage" when the lever is pushed 90 degrees down. I had simply forgotten the 3rd position, which is to slide the entire lever "Downward" as the final motion to engage the two small pins for the "Low-Voltage Interlock Loop".​

It took about 3 power-ON-cycles to get the car to "realize" that the Service Plug Interlock Loop was made, with each try, I heard more relays clicking-in, especially from within the Traction Battery. At this point, all the warning lights went out, the "READY" message appeared, the engine started and I was able to switch into Drive and Reverse.​

Yahooo! What a relief!​

​

Read more: http://priuschat.com/threads/big-red-triangle-and-other-warning-lights-wont-go-into-drive-reverse.116365/#ixzz2H1LH0bgx​

It looks like once you get it installed properly, it takes 2 or 3 cycles of the ignition switch to get everything synched back up.

 

Here's a good PDF on installation. Pay close attention to the last step (step 9. (c)) on pg 21-118.

 

Congrats on your success.

Pls say more about these strange noises. The inverter usually will make a whining sound when the Prius is READY, and the sound will vary depending upon the load on the inverter. The inverter coolant pump will sound like an aquarium pump.

 

I knew it.!!!!

 

Good one navy!!

 

Hearing water movement in the car is air trapped inside the engine coolant loop. Your hearing cavitation in the heater core box under the dash. You must have changed the engine coolant somewhere along the line and never got the air out. Its very hard to get all the air out of the engine coolant on this car given the CHRS. Many many posts here on how to do it.

Please be aware your probably overheating the engine. There is no dash thermometer so you will not know this until the engine reaches very hot level and throws a cel.

Be careful here. Easy to damage the aluminum cyl head. This is where a scan gauge really pays off.

 

If you don't see any warning lights on, then I suggest you drive the car as-is for a while and see what happens. The problem may not be related to the inverter. More likely, the sound is caused by the brake actuator assembly mounted on the firewall behind the inverter.

If you have the cabin heater on and hear air bubbling sounds, then I would agree with Ed. Otherwise, it is possible that you have water trapped either in the cowl pan where the windshield wiper motor is located, or within a door, and as the car is moving around the water is sloshing back and forth.