Car wont Start after Changing Battery Cells

welcome! if you're positive the orange connector is in correctly, i would go back and test the new silly putty connection. that seems like the most likely culprit. all the best!

 

Before you strip down the pack again, did you try pressing the power button twice when you had the brake pedal depressed? This is required to get the Prius into the READY condition.

Let us know if/when you get it corrected and what it was. Always helpful for the next person who attempts this DIY repair.

 

Having 30+ years experience in electronics/electrical work, all I can say is: Are you kidding me? You broke the threaded stud on a module and used steel putty to put it together? Did you break any wires and put them back together with gorilla glue? Maybe a hole in a radiator hose that you fixed with duct tape? I don't want to be disrespectful, but THIS IS THE EXACT REASON SOME DIYers SHOULD NOT TOUCH SOME JOBS. If you don't comprehend the possible consequences of a solution like this, you shouldn't be touching this job. This is no joke, to even think this could be satisfactory blows my mind. Even if you were able to get a good enough electrical connection that the sensors didn't pick it up, it has to be a fire waiting to happen due to a high resistance connection. This is a job that has to be done RIGHT, otherwise you put yourself and others at risk of breaking down, causing an accident, or causing an electrical fire in your car. Good GOD, this made my blood pressure spike!!! I'm not one to call someone out, but this is crazy.

 

You got some help and teaching on how to avoid frying yourself. The modules can be had on Ebay for pretty cheap. 200 Volts DC is nothing to sneeze at can put you in a grave or a hospital pretty quick it's nothing like 110V AC.

 

There's more to a successful repair of a failed HV battery than just checking the open circuit voltage of each module and replacing known bad modules. Much more.

Did you get the diagnostic trouble codes from the OBDII port underneath the dash by the steering wheel after the latest incidence of warning lights? This is the first thing you need to do to determine what's wrong with the HV battery this time around.

It seems that you are either in a big rush to complete this repair because you don't have another vehicle to drive in the mean time or because you haven't learned enough from the best thread on this issue - Gen II Prius Individual Battery Module Replacement | Page 85 | PriusChat by ryousideways. This thread provides most of what you will need to know and do. There are other related threads that are also helpful.

Unless you make the effort to learn the proper way to do a DIY HV battery repair, it's highly unlikely that you will be able to do one that will last several months.

Do it right or don't do it at all.

 

what happen with the silly putty connection?

 

Fedx2525, you are like a drowning man who is desperate for help but won't grab onto the life preserver.

One more time (and that's it). The open circuit voltage is not all there is to this. You need to determine the
capacity of each module under load to find the weak ones. Once you have, you can try to recondition them
or replace them. If a module self discharges too quickly, it must be replaced.

If you don't want to do the work correctly - hire someone who will. Before you drown. Sheesh.

 

Okay, maybe your HV pack is beyond hope. Too many Texas summers (and falls, winters, and springs).

Since you seem adept at replacing modules, why not buy a new pack from a Toyota stealership.
New packs can be had for as little as $2000 with tax or Texas Hybrid Batteries LLC could install it for you for $2199 tax included.
Texas Prius Battery Replacement

Your Prius might last many more years with one (assuming nothing else is wrong with it).

 

We just did a refurb on our prius battery. Taking it out, took all the cells apart and balanced them all. We then put it all back together, getting good 220V from the hybrid battery and 12.3 out of the standard 12v battery. Car would not start.

1) As all the posts above, check the orange connector. It not only goes IN, but then has to be pressed DOWN to fully connect.
2) Turn on your car and make sure all the codes have been cleared. If you don't know how to do this, search the internet, pretty straightforward, clear your codes.
3) For those of you who have not done this, rebalancing the battery takes about a day per cell, and you have 28 cells to go through. So our car sat for about 6 weeks while we were doing the rebalancing. When everything was hooked back up it seems the hv relay was a little "sticky" and would not engage. There is no code that comes on, it's just the car will not start and all the warning lights are on. After troubleshooting it appears the hv relay is a key component of the hybrid system and allows the hybrid battery to connect to your car (it disconnects when you turn the car off.) It needs 10.8v to activate this relay, so make sure your 12 v battery is in good shape. You should hear some "clicks" when the relay activates when you push the power button. If you don't hear the clicks, the relay is most likely stuck. You can gently tap on these to help jiggle free the stickiness until they start clicking. Don't pound, this is an electronic device and can be damaged. Once we heard the clicking, the car came alive and all the warning lights disappeared.

Hope this helps someone.

 

Thanks for the information. It might have helped when this thread was last active... In 2016 but I’m pretty sure it’s been worked out since the OP has not logged in over 2 years.

 

This isn't a case of re-stripping a frayed wire going to your headlight. You broke a battery module. Then you thought it was more feasible to go it alone instead of coming here. If you learn never to do it again, the critic is justified.