Which parts fail
Components named in complaints (engine, cooling system, oil leaks, timing chain, exhaust).
Mileage when the problem started
Owner reports
Selected complaints filed with NHTSA by 2004 GMC Envoy XL owners, lightly cleaned up (personal details are redacted by NHTSA).
The contact owns a 2004 GMC Envoy XL. The contact stated while driving approximately 45 MPH, the accelerator pedal was depressed, and the vehicle stalled. Additionally, the vehicle failed to restart, with several unknown warning lights illuminated. The vehicle was towed to the residence. The vehicle was not diagnosed or repaired. The manufacturer was notified of the failure and suggested that the vehicle be inspected by a local dealer. The failure mileage was unknown.
I was driving and my vehicle on I-985 hall county ga. My check gage light came on and less than 1/2 of a mile it start to smoke and burn as soon as I stopped turned of the ignition. It burnt to the ground from the engine area to the inside.
Was driving and service engine soon and reduced engine power loss came on. The car basically starting shutting down but I was able to coast out of traffic before it stopped completely. Turn it off, back on several times, until the lights went off then drove it home. I've replaced the throttle body twice and the gas pedal for the sensor located behind it. Went from happening sporadically to almost everytime I drive it. Can't drive 3 miles without reduced engine power loss coming on. Now there's about 155,000 miles on the vehicle and it's happening all the time. Needless to say, it's sitting on the driveway. I'm aware other customers are having this same issue from reading comments online. I don't understand why GM has not done a recall to fix the issue. Perhaps it can't be fixed.
Hello, hope you can help myself and other persons from not happening. I came home from work Saturday, and parked in the garage as usual. After being home and watching some tv I know for sure was 2 in a half hours. My wife asked of me to go to the garage to get some ice cream, we have a freeze in there. I walked in the door and couldn't believe how hot! It was in there it wasn't a hot day at all to make the garage sizzle. We have a thermometer gauge in there and believe me it read 100 . I was shocked! I went into the house to get my wife, to let her feel the heat, and try to find the source of the problem. We both thought it was the freezer, because that's the only thing plug in. We felt the freezer from the outside , in some places it was hot. I couldn't take the heat any more and opened the garage door. There was no smell of anything that could be wrong. …
2004 GMC Envoy xuv dies when in drive and stopped for stop light, stop sign, etc. When the gas is applied, the car dies and I tie up traffic while having to shift to park, restart the engine, and then shift to drive and proceed through the intersection. It never dies while driving, only at a stop. I have had this car to the dealer numerous times and, because there is no "code" , they don't know what to do to fix it. The car also has a gas tank that is cracked at the neck and causes the check engine light to be on all the time. The dealership assures me that this is not a safety concern nor does the gas tank crack have anything to do with the engine dying. There is no gas leak but air does get into the tank causing the light to stay on. The throttle body has been cleaned and the entire emission system has also been checked and no one can figure out what the problem is. …
Well lets just say after receiving the Envoy back from the dealer for replacing the gears in the transmission in which GM did not find to be at fault for not checking the transmission @ 31,000 miles when I had problems with it not shifting correctly. So over the next months following this my transmission went out @ 52000 miles, so GM had me pay a 500 deductible. Now my service engine light is on for the coolant system according to on-star, so back off to the delaership for not checking all the codes for the service engine light. I have already had to replace the fuel filter inside the gas tank, the gas tank neck, the battery @ 38,000 miles, and tires @ 28000 miles, brakes @ 38000 even when I asked the dealership to check the brakes and complained 3 times about the brakes. …
For the last few months the check engine light would come on and go off after a few days; we took it to our mechanic who ran a diagnostic and they said there is nothing wrong, probably a faulty sensor, not harmful. So, last night while driving, using cruise control and on the interstate my speedometer stopped working. When I came to a stop at an exit I noticed the speedometer was reading 42 MPH but I was at a complete stop. I do not even want to imagine what might have happened should it have begun to work while I was doing 60+MPH while on cruise control!!! This is extremely dangerous! So I came home and did some research to see if this is a known issue with my 2004 GMC Envoy XL and low and behold this is an issue to all GMC suvs from 2002-2005! …
I heard a clicking noise from under the hood and after pulling off the cover plate for the engine exhaust manifold I saw the manifold was cracked. At idle speed fumes get inside vehicle. Repair has not been made so old part is available. Upon research on the internet there are numerous other complaints of this problem. I sent an e-mail to GM and someone called and said they need more people to report it to get something done. I believe it is a safety issue because of the fumes and possible fire hazard.
Started to hear loud rattle coming from rear of vehicle, thought maybe a heat shield around muffler went bad. Took it into the shop and they stated "not sure what happened, though you have something that has come loose in the resonator". Around $100 to get the resonator removed, have not quoted a new one from the dealer yet. I would imagine the replacement part will fail just as the original part has done.
My GMC's service engine soon light went on and I took into the shop. They stated that there is a fuel issue for the fuel cap and that the fuel tank needs to be replaced because it leaks. This is a manufacturers defect and this part should never "wear out" over time or due to the number of miles driven. GMC needs to stand behind their vehicle and replace this part for free!
Engine complaints in other Envoy XL years
Frequently asked questions
How common are engine problems on the 2004 GMC Envoy XL?
NHTSA has 20 complaints about the engine & cooling of the 2004 GMC Envoy XL, 11% of the model year's 187 complaints. The component named most often is exhaust system (3 mentions).
Is there a recall for 2004 GMC Envoy XL engine problems?
No. NHTSA lists no engine & cooling recall for the 2004 GMC Envoy XL, though it has 1 recall for other components. If the problem is widespread, a repair may still be covered by an extended warranty or a manufacturer service bulletin — ask a dealer.
At what mileage do 2004 GMC Envoy XL engine problems start?
Half of the complaints with a recorded mileage happened before about 81,000 miles, and 7% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 2 fires and 1 injury to engine & cooling problems on this model year. If you notice symptoms, have the car checked before driving further.
Source: U.S. National Highway Traffic Safety Administration (NHTSA) — owner complaints through October 20, 2026, recalls and defect investigations; fuel economy from the EPA. Complaints are unverified reports and are not proof of a defect. How we rate model years.