Letter from Toyota on P3190 P3191 and P3101 & code 204 & 205 - Toyota Prius Forum : Prius Online Toyota Forums
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post #1 of 11 (permalink) Old 08-11-2009, 10:30 AM Thread Starter
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Default Letter from Toyota on P3190 P3191 and P3101 & code 204 & 205

FYI...

Just got a letter from Toyota that they are extending the warranty coverage for the codes P3190 P3191 and P3101 & code 204 & 205. 10 years or 120K miles for 2001 to 2003 Prius.

I've gotten such a code (engine did not start) once or twice for the past year and had just reset them with my scanner... I've never experienced the "slow down" aspect of it though, so I think mine were just a fluke (I have the latest CPU as far as I know).

Unfortunately, I bought the car at 116K miles and I am already at almost 150K so I may be out of luck!

Which parts are they replacing for the repair *now*?

Thanks!
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post #2 of 11 (permalink) Old 08-13-2009, 03:35 PM
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Default Re: Letter from Toyota on P3190 P3191 and P3101 & code 204 & 205

I have had both 3190 and 3191. Don't remember what 3190 was; maybe the inverter cooling pump, but that's just a guess.

I am pretty sure 3191 was "ICE failed to start". That was from the dealer overfilling the engine oil, and some of it got sucked into the throttle-plate area (or something like that). It was probably aggrevated by the extremely cold weather at the time.

There is a post on both of these failures somewhere in the archives on this site.
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post #3 of 11 (permalink) Old 08-17-2009, 06:00 PM
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Default Re: Letter from Toyota on P3190 P3191 and P3101 & code 204 & 205

3191 Engine (aka ICE) does not start.
3090 Poor engine power.
3101 Engine system malfunction
204 Abnormal engine output (abnormal signal from ECM)
205 Engine unable to start (due to abnormal signal from ECM)

Bottom line, if your engine does not start and one or more of these DTC codes come up, you are covered by the extended warranty. I assume that they will replace or repair whatever part necessary to get your engine going.
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post #4 of 11 (permalink) Old 09-01-2009, 08:27 AM
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Default Re: Letter from Toyota on P3190 P3191 and P3101 & code 204 & 205

I have gotten this code twice now on my 2001 and both times the dealer replaced the gas tank and the ECM per Toyota TSB EG011-03. The first time they replaced it for free because Toyota felt that it happened prematurely at 68,000 miles. The second time it cost me $1400 because I was completely out of warranty. I am hoping to get my $1400 back due to this letter since it happened at 114,000 and within 10 years. I have my fingers crossed as this came at a time that was not convenient to spend $1400 on my car. My car died and would not start and I had all of the lights on on my dash.

Brian Turner
2001 Prius
134,000 miles
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post #5 of 11 (permalink) Old 09-02-2009, 03:12 PM
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Default Re: Letter from Toyota on P3190 P3191 and P3101 & code 204 & 205

Good luck; keep us posted on what happens...
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post #6 of 11 (permalink) Old 01-06-2010, 09:00 AM
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Default Re: Letter from Toyota on P3190 P3191 and P3101 & code 204 & 205

For the first few years, at least once each winter my 2002 Prius wouldn't start at first (or it started and then stalled after 30 sec) after sitting outside over a really cold night. Then last winter it started happening more often, even when the car had been in the garage. My MiniScanner says P3191 and P3101 every time. I took it into an independent mechanic I'm very happy with, and he diagnosed a puddle of oil in the intake manifold. He explained it was being sucked into the engine at start-up and retarding the pistons. If it was cold enough, the oil became very thick, and the extra strain on the engine caused it to shutdown. (The oil is probably there all year, but it's only thick enough to be a problem in winter.)

He had to disassemble a lot of the engine to get in there and clean it out (about $500), and it didn't seem to work at first (probably there was still some oil deeper inside), but within a week or two the problem disappeared, and it started fine the rest of the winter, even after sitting outside on some very cold nights.

This winter, the problem has returned. My mechanic stuck a borescope in through some small hole and confirmed more oil in the intake manifold, so I guess I'll have to pay another $500 to clean it, but I'm wondering where is this oil coming from? I change my own oil, and I never put in more than 3.5 quarts, so I know it's not being overfilled. I'm just past 120k mi, so I'm past the cutoff for the warranty service. Does anyone know what the Toyota mechanic will repair or replace as part of this warranty? Bturner425 mentioned a new gas tank and ECM, but that doesn't seem to be connected to an oil leakage.

Has anyone else dealt with oil puddling in the intake manifold of a Gen I Prius? I'm tempted to just ignore it, because the car always starts eventually (sometimes after 5-10 power cycles), but it's a nuisance when it happens several mornings each week. Also, I fear this might cause some additional problems, such as reducing my gas mileage, clogging my catalytic converter, etc.

Douglas (2002 Prius)

Douglas (2002 Prius, 2006 Highlander Hybrid, Wisconsin)
-----
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post #7 of 11 (permalink) Old 01-06-2010, 02:13 PM
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Default Re: Letter from Toyota on P3190 P3191 and P3101 & code 204 & 205

That's the symptoms that we had on our 2002 Prius in Flagstaff several years ago.

At the time, our Phoenix dealer told us to have the Flagstaff dealer reset the codes and get the heck out of there, as they wanted to clean out the throttle-body or something like that to remove the excess oil. And, the Flagstaff dealer wanted about $800-1,000 to do that. There were about 8 or 10 Prius's in that shop that morning, all for the same thing, so I think the dealership had a pretty good day (money-wise).

After I got back to Phoenix where it was warm, the Phoenix dealer drained about a half-quart of oil out (they had overfilled it to 4 quarts during the last service), and it never happened again. However, they continued to overfill it every time they changed the oil during the free service (our Prius got free oil changes for about 50,000 miles or so). I checked it before driving off, and had them drain part of it, before I drove off the lot -- every time.

Now that our Prius is long out of warranty, I do all the routine maintenance myself, making sure not to overfill the oil. However, we now drive a 2008 Tundra on all of our roadtrips, so our Prius hasn't seen snow in several years. The Tundra and an Airstream now go on all of our roadtrips. I miss the mileage on the Prius, but save the hotel money camping in the Airstream, to where it is a wash, either way. And, the Airstream makes for a lot more leisurely drive (although slower).
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post #8 of 11 (permalink) Old 10-03-2010, 01:48 PM
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Default Re: Letter from Toyota on P3190 P3191 and P3101 & code 204 & 205

does anyone have a copy of this letter? Our 2001 threw these codes and I figured my Toyota dealership knew of the extension so I brought it in. I got an earful of how it was going to cost $115 to "diagnose" and I mentioned how I'd spent a few hours researching it before bringing it in and there was a 10yr/120mile extension on this issue.

I was later told there was no extension and they determined the cause was a dirty intake manifold from oil in it and that would cost around $300 to clean up. Along with the $115 "diagnosis" of the problem. I had figured they'd just do a throttle body cleaning or maybe the ECU replacement so we don't keep seeing this in the future but that's not what happened.

If someone has the letter extending the coverage, please post a scan here or PM me so I can bring this to the dealer. thanks.

d
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post #9 of 11 (permalink) Old 10-04-2010, 10:48 PM
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Default Re: Letter from Toyota on P3190 P3191 and P3101 & code 204 & 205

I just went through all this same drill with my 2001 88,000 mi. Same codes would come up, just at random, some times after just starting in the garage, occasionally at a stop in town, at random and only every other month or so.
After 4 trips to the dealer and reseting codes each time mechanic suggested changing the ECU to an updated later version that MAY cure the problem. All this for a quoted $1100. When I objected he remarked there is always E-Bay.
Picked up a late version ECU on E-Bay to install and just had no time yet to install it. Car stalled in town again near the dealer this time, brought it in, same codes. Mechanic looks up some service bulletins and then takes a look into the throttle budy/intake manifold and says----found the problem, oil in the manifold. Asked who was doing my service and when I told him--you guys are-- said ok will fix and no charge!
Suggested I replace the ECU sinse I already have it so I did that. No problems sinse but keeping my fingers crossed.
I suspect the later ECU is less sensitive to engine not starting codes but that is just a guess on my part.
Sounds like they have had a lot of complaints about this and are starting to respond. Very interesting.
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post #10 of 11 (permalink) Old 10-04-2010, 11:57 PM
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Default Re: Letter from Toyota on P3190 P3191 and P3101 & code 204 & 205

Quote:
Originally Posted by Paul01
I just went through all this same drill with my 2001 88,000 mi. Same codes would come up, just at random, some times after just starting in the garage, occasionally at a stop in town, at random and only every other month or so.
After 4 trips to the dealer and reseting codes each time mechanic suggested changing the ECU to an updated later version that MAY cure the problem. All this for a quoted $1100. When I objected he remarked there is always E-Bay.
Picked up a late version ECU on E-Bay to install and just had no time yet to install it. Car stalled in town again near the dealer this time, brought it in, same codes. Mechanic looks up some service bulletins and then takes a look into the throttle budy/intake manifold and says----found the problem, oil in the manifold. Asked who was doing my service and when I told him--you guys are-- said ok will fix and no charge!
Suggested I replace the ECU sinse I already have it so I did that. No problems sinse but keeping my fingers crossed.
I suspect the later ECU is less sensitive to engine not starting codes but that is just a guess on my part.
Sounds like they have had a lot of complaints about this and are starting to respond. Very interesting.
When the service writer told me of the oil in the intake manifold I immediately told him that every time I had Toyota do the oil change I had to let out .5 qt at home because they always put too much and that was what caused the oil-in-manifold problem. I didn't get the impression he accepted my explanation and probably didn't believe me. From what I heard about the xxx54 model of ECU it gave the engine a little more time to start and that's how they fixed the issue. Sounds like your dealer or at least the mechanic got the idea that they were messing up the car by over filling the oil pan. Too bad it still cost you all that time and the cost of a used ECU. So, how much did you end up paying for the ECU?

d
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