During a recent road trip my 2011 Highland Hybrid Limited quit while driving 65-75 mph. It happened twice about 1000 miles apart on different days. While driving I got the warning light, check engine light, and a message to check the hybrid system, pull over immediately, call the dealer. 1st time I became so annoyed with trying to get "Toyota" road service that after 45 minutes or so, I tried to start the car and it did although the check engine light was on. Went to Toyota dealer 20 miles away and they said there was no code so they didn't know what it was. They reset the check engine light and said drive on. Second time the same thing happened with no dealer for 80 miles. I dutifully waited 45 minutes and it started again with check engine light still on. Drove to the city and waited until morning to take car to dealer. When I went to start it in the morning the check engine light was not on and there was no evidence of any issue. The next dealer kept the car for 3 hours. Service record said "hooked up Tech Stream and pulled code P3190 P0A0F SUB 204, Inspected all in specs, fuel pressure good at this time, cleared codes, road tested, could not duplicate at this time." They said essentially the same thing as the first dealer, except they said they specifically checked the inverter and said it checked out. The service manager said the only code they found was to change air cleaner. This is a dangerous problem and the vehicle doesn't record it. It seems to me to be some kind of cooling issue that after time resets. The vents in front of second row seats were clear, but service manager said that wouldn't affect the inverter, anyway. Has anyone ever had this experience? Any other ideas?
randybump
P313 HYBRID VEHICLE CONTROL: HYBRID CONTROL SYSTEM: P0A0F-204, P0A0F-205, P0A0F-206, P0A0F-524, P0A0F-525: Engine Failed to Start
P0A0F-525 - Engine Failed to Start
DESCRIPTION
If an engine malfunction occurs, an engine malfunction signal is sent from the ECM to the hybrid vehicle control ECU. When the hybrid vehicle control ECU receives this signal, it sets a DTC and performs fail-safe control.
HINT
If P0A0F-204, 205, 206, 524, or 525 is output even though the ECM has not detected a malfunction, there is a malfunction in the hybrid vehicle control ECU.
2GR-FXE ENGINE CONTROL SYSTEM: SFI SYSTEM: P3190, P3191, P3193: Poor Engine Power
P3193 - Fuel Run Out
DESCRIPTION
From the hybrid vehicle control ECU, the ECM receives data such as power output required for the engine (required output), estimated torque produced by the engine (estimated torque), engine speed of control target (target engine speed), and whether the engine is in start mode or not. Then, based on the required output and target engine speed, the ECM calculates a target torque that is to be produced by the engine and compares it with the estimated torque. If the estimated torque is very low compared with the target torque, or the engine start mode continues for the specific duration calculated by the coolant temperature, an abnormal condition is detected.
This is followed by very lengthy inspection with a lot of possible causes for fail fuel supply. Fuel lines, EGR, fuel filter, fuel pump, etc. It's a LONG procedure. There's a bunch of subcodes that, when showing, point towards which part is failing.
Gist to it is - your engine failed to operate because of the fuel supply cutout.
P0A0F-525 - Engine Failed to Start
DESCRIPTION
If an engine malfunction occurs, an engine malfunction signal is sent from the ECM to the hybrid vehicle control ECU. When the hybrid vehicle control ECU receives this signal, it sets a DTC and performs fail-safe control.
HINT
If P0A0F-204, 205, 206, 524, or 525 is output even though the ECM has not detected a malfunction, there is a malfunction in the hybrid vehicle control ECU.
2GR-FXE ENGINE CONTROL SYSTEM: SFI SYSTEM: P3190, P3191, P3193: Poor Engine Power
P3193 - Fuel Run Out
DESCRIPTION
From the hybrid vehicle control ECU, the ECM receives data such as power output required for the engine (required output), estimated torque produced by the engine (estimated torque), engine speed of control target (target engine speed), and whether the engine is in start mode or not. Then, based on the required output and target engine speed, the ECM calculates a target torque that is to be produced by the engine and compares it with the estimated torque. If the estimated torque is very low compared with the target torque, or the engine start mode continues for the specific duration calculated by the coolant temperature, an abnormal condition is detected.
This is followed by very lengthy inspection with a lot of possible causes for fail fuel supply. Fuel lines, EGR, fuel filter, fuel pump, etc. It's a LONG procedure. There's a bunch of subcodes that, when showing, point towards which part is failing.
Gist to it is - your engine failed to operate because of the fuel supply cutout.
They simply need to do expanded diagnostics on that code. It takes a lot of steps, but pinpoints what's wrong. Personally, I'd have replaced fuel filter and ran 2 consecutive cans of Seafom through tankful. 1 tank, 1 can. That will clean entire fuel supply system well. As a general notice, personally, I am avoiding cheap gas stations. And Seafom fuel system about once a year.
I used Amsoil fuel treatment at the beginning of the trip and was using Top Tier gasolines for about half the trip, but since I bought the vehicle 3 months before the trip (certified used car from Toyota) I assumed the filter was current - maybe it's not. Maybe the dealer thought all the problems could be dealt with by the new owner under warranty with Toyota reimbursing them for all the repairs....hmmm?
Donno. I have never heard of them quitting like this. You the first one. Another step could be simply re-flashing ECM with OEM s/w. Maybe ECM got some bug. Honestly, I replaced several fuel filters and they always were good, so I simply stopped replacing them and clean fuel system with Seafom ever so often. I trust nothing but Seafoam since 2002.
Sounds like you are under warranty. Let them have it. Take it back and raise voice. Tell them to run complete diagnostic on that code. Drive a loaner meantime. It should take them few hrs. It's too many pages to post here and why? They have same info I do.
Don't start doing haphazard replacements on a hunch. Diagnose it. You don't want to get caught somewhere in the mountains mid winter.
Sounds like you are under warranty. Let them have it. Take it back and raise voice. Tell them to run complete diagnostic on that code. Drive a loaner meantime. It should take them few hrs. It's too many pages to post here and why? They have same info I do.
Don't start doing haphazard replacements on a hunch. Diagnose it. You don't want to get caught somewhere in the mountains mid winter.
OK, here's the deal. The local dealer found code P0A0F also and informed me that there was a service bulletin for it that wasn't normally covered by the hybrid warranty (except in California). The certified used car warranty expired during my trip due to miles but the dealer partially honored it. The recommended solution was to replace the intake air surge tank assembly and reprogram the ECM. If there is a repeat then the next step is to replace the ECM. Service was performed, but because of the infrequent and intermittent occurrence of the problem, there's really no way to say that anything was solved or not until and unless it recurs.
http://carspecmn.com/2001-2009-prius-p3191-p3190-p0a0f-quick-checks-for-toyota-prius-mil-repair/
I understand that is for Prius yet.... A Toyota is a Toyota.
I understand that is for Prius yet.... A Toyota is a Toyota.
Just experienced this error code P3190 on my 2008 HH. We were running over a couple of high mountain passes in CO 10,000ft at speed on the way out but the code only appeared on the way back on the flats when starting up from a stop for gas - Running 85 gas 
Of course I ignored the message about pulling over and taking the car to the dealer! The car was running fine and did not quit on me. I appear to have
reset the code by holding down the display button while the car is starting up.
Any thoughts? I only have one of those cheap little Bluetooth OBD two readers so perhaps they were other error codes I didn’t see any. I only have one of those cheap little Bluetooth OBD2 readers perhaps they were other error codes - I didn’t see any. There is a Toyota service bulletin but it only talks about 2017/18 Highlander’s running at altitude showing this error.
The only thing I did notice was that the battery indicator was empty for a least an hour and a half and only regenerated towards the end of my trip. We were going down some pretty major hills and it seemed to top up the battery very slowly even when braking.
Odd! I was bragging about how this is the first car that I’ve owned that does not Have check engine light on, boy was I wrong. Every single car previously it was a simple catalytic converter error but now this seems scary hybrid battery system - Toyota so reliable
Of course I ignored the message about pulling over and taking the car to the dealer! The car was running fine and did not quit on me. I appear to havereset the code by holding down the display button while the car is starting up.
Any thoughts? I only have one of those cheap little Bluetooth OBD two readers so perhaps they were other error codes I didn’t see any. I only have one of those cheap little Bluetooth OBD2 readers perhaps they were other error codes - I didn’t see any. There is a Toyota service bulletin but it only talks about 2017/18 Highlander’s running at altitude showing this error.
The only thing I did notice was that the battery indicator was empty for a least an hour and a half and only regenerated towards the end of my trip. We were going down some pretty major hills and it seemed to top up the battery very slowly even when braking.
Odd! I was bragging about how this is the first car that I’ve owned that does not Have check engine light on, boy was I wrong. Every single car previously it was a simple catalytic converter error but now this seems scary hybrid battery system - Toyota so reliable
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