2002 Prius - no start with recently rebuilt hybrid battery

I've been lurking around here checking posts and gleaning what I can when I need to work on my car, but I haven't joined until now.

My 2002 Prius has 245k miles on it. Earlier this year while using the "B" to charge the battery pack while coasting I heard a bang from the back. I eventually got around to removing the hybrid battery to find an exploded module, blew a nice big crack in one of the 38 battery modules. I tested a few of the other battery modules and ended up replacing about 13 of them with eBay battery modules.

The car sat for about 2 months because life got in the way, work went through some crazy stages and i could give about 2 or 3 other excuses. I finally got around to putting the hybrid battery back in two days ago. But now the car won't start. I have the 12V battery on a charger, it was replaced at the same time I just put the hybrid battery back in.
Now the READY doesn't display on the dash and I have check engine lights for P1636, P3002, and P3030. I'm using an OTC Genisys to pull the codes, I can't seem to get the custom data stream up for being able to read the battery SOC or module pairs.

Any help from you fine people? I think I may have to take the battery out again and go through the connections

 

4est, you might be right about that HV safety fuse, I'll go run out and check that thing.

Ray, I only reassembled it. I don't have the proper chargers to do the Prius batteries. I have a few IMAX B6 chargers around here, but I don't think they'll work for the Prius. The 12V battery is about a year old, currently on a charger. I can let you know what the battery voltage is tomorrow morning when I've finished charging the 12V battery.

 

I went out and checked it by pulling it and replacing it. It was in there as firmly as it will go. Thanks for the suggestion though, I was hoping that was it...

 

@Tideland Prius or other moderators: looks like my reply posts are being held up
"this message is awaiting moderator approval, and is invisible to normal visitors."

 

@4est, I have a first gen prius. The video you sent is for the 3rd gens, slightly different. Mine just pushes in and has a horseshoe clip that rotates 90* to lock it in place

@Brian in Tucson, this is my personal car. I don't think my max b6 chargers can do the prius batteries. I tried it a few different ways but it doesn't have the right settings to not swell the battery modules. Is there something I missed and maybe I can use the IMAX b6 chargers to cycle the Prius modules back to good health?

@Raytheeagle, same question to you. Can I use the IMAX B6 chargers to cycle the Prius batteries?

 

@Brian in Tucson, I'm in the Sierras about 3 hours east of Luscious Garage. I'm not yet that desperate to put the car back together. As a lifelong mechanic myself, my pride and my wallet unfortunately prevent me from physically taking the car to another shop. It's not out of the question but I'll hold off until I'm too frustrated to continue working through it myself.

 

alright all, I just bought the VCI cable, it will arrive on Friday.

Edit: does anyone know why I keep getting "this message is waiting on approval from moderators"? message?

 

I did try using the IMAX B6 for the modules (note: it worked wonders for the Honda Civic Hybrid battery modules) but it seemed to overcharge the Prius battery modules every time. I can't find where I can limit the voltage on it. The rate of charge was fine but the IMAX chargers would charge around 8.7V - 9.5V IIRC, and the prius battery modules would swell if I left the charger on for more than say 20 minutes.

 

Eric, thanks so much for all the good advice. The problem I'm up against at the exact moment is that I can't get the car to display READY on the dash. I turn the key, I can see all the dash lights, but no READY. And the check engine light is on, showing codes P1636, P3030, and P3002. I think once it gets showing READY, I can get the poor bugger started.