Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
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).
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.
Vehicle was taken in for oil change and I was advised it had a crack at the neck of fuel tank. Upon further research there has been a recall for this very same problem on the same vehicle. Vehicle was never in a accident or anything that would cause this.
My Envoy has had the check engine light on for years, and the smell of gas, went to GMC and they said need new gas cap, didn,t work, went to another car repair need new gas cap, same thing over and over again, every month on my OnStar report, said I had emission problems, they tested the car, looks like it could be you need a new gas cap..... A few months ago my GMC would not start, call aaa to pick up Envoy and take in the charles shop near my home.... As the auto was being put on the trailer, I saw gas dripping from the area of the gas tank....went to charles repair to them about what I saw and explained that for you I have been trying to find out what was wrong with the gas cap, and the smell of gas... …
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. …
I have a 2004 GMC Envoy xuv and when the oil was just recently changed the mechanic noticed that the gas tank was leaking at the point where the filler met the main body of the tank. He said since the tank was plastic the gas was causing the deterioration and the entire tank would cause a major issue. After checking with our local GMC dealer I discovered that the vehicle is just out of the 3 yr warranty period and since it was purchased in arizona and not california it is not covered under the extended GMC warranty. This should not be part of a replacement plan the consumer should be paying for, not like a regular maintenance item (changing tires, oil changes, spark plugs, etc.) cutting corners to make the vehicle lighter and then not supporting the change is not the best way to be popular.
Special coverage adjustment fuel tank inlet check valve fracture #07099a. Issued August 24, 2007. My 2004 GMC Envoy is now experiencing this problem. I was never notified of this as GM claims they did not know I was the owner of this car. I bought it used in 2005. I was told by a mechanic when I took it in to check out the problem that I should not fill the gas tank full as it could cause gas leakage. I am also facing an expensive bill to get this fixed. A recall was never issued and it appears this is a life safety issue. I would appreciate your attention in this matter.
Vehicle's "check engine" light came on 2 days prior to failing a vehicle emissions test for fuel tank leak. Dealer stated that there was a "special policy" in place as the manufacturer recognized this same defect on other vehicles. The VIN number was not included in the "special policy" but was the same defect. The dealer is advising not to continue to drive the vehicle until repaired. The dealer opinion is that due the "special policy" there are no fuel tanks available so the vehicle ia located at the dealer until repaired. Old part can be made available.
Tl contact owns a 2004 GMC Envoy. The odor of gas was present in the vehicle at a stop sign. The dealer stated that the fuel pump corroded with rust causing the pump to spray fuel to the top, penetrate in the undercarriage, and the exhaust system. The contact assumed the cost of $444 to replace the fuel pump. The manufacturer advised him that there is no related recall. The current and failure mileages were 42,500. Updated 02-14-08 the consumer stated the labor cost was in the amount of $220 extra. Updated 02/14/08
Tl* the contact owns a 2004 GMC Envoy XL. The contact was driving approximately 30 MPH as the fuel gage displayed an incorrect reading. The failure recurred at any time. The contact had taken the vehicle to the dealer where they replaced the fuel tank yet the failure continued to recur. A complaint was filed with the manufacturer regarding the fuel tank but no assistance was provided. The failure mileage was 84,000.
Tl* the contact owns a 2004 GMC Envoy XL. The contact stated that while driving approximately 30 MPH, she noticed that the fuel gauge reading was fluctuating while the fuel tank was full. The engine then suddenly stalled due to the faulty fuel gauge. The vehicle was not diagnosed or repaired. The manufacturer was not notified of the problem. The approximate failure mileage was 101,000.
NHTSA investigations
Fuel pump module leaks gasoline
During the course of this ea investigation, odi observed that the majority of the complaints (88%) and warranty claims (94%) were reported for vehicles that are registered for use in the salt belt region of the us.this area includes 20 states in the northeast, mid atlantic and the midwest regions and the district of columbia.consumers in the salt belt region reported to odi that they could smell fuel vapors in their…
Fuel System complaints in other Envoy XL years
Frequently asked questions
How common are fuel system problems on the 2004 GMC Envoy XL?
NHTSA has 28 complaints about the fuel & propulsion system of the 2004 GMC Envoy XL, 15% of the model year's 187 complaints. The component named most often is storage › tank assembly (3 mentions).
Is there a recall for 2004 GMC Envoy XL fuel system problems?
No. NHTSA lists no fuel & propulsion system 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 fuel system problems start?
Half of the complaints with a recorded mileage happened before about 101,000 miles, and 4% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 1 fire and 1 injury to fuel & propulsion system 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.