Fuel System complaints by model year
Which parts fail
Components named in complaints (fuel pump, injectors, fuel tank, hybrid and EV propulsion).
Mileage when the problem started
What owners report
Filled SUV up at gas station. Gas gauge went to full. Proceeded out of gas station when the gas gauge went to empty, gas gauge will now not stay in one place, continues to act up and mostly stays on empty and the bell rings constantly. I am unable to determine how much fuel I have and concerned that the SUV will think its out of gas and shut off.
Driving on the highway after putting fuel in and fuel gauge suddenly shows empty and my vehicle stalled. The fuel guage would then show full at times then empty. Now it shows empty all the time and has stalled 3 more times while driving in traffic.
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 dad was driving his 2003 GMC Envoy XL home from work and he felt a small explosion and saw black smoke out of his rear view mirror. So he pulled over, got out, and there were flames underneath the car. Within 5-10 minutes the car exploded. A fire fighter and state trooper pulled over to help him, and they both said the fire looked like it started from a fuel leak because the flames were "dripping" under the car. After researching recalls and complaints, I am infuriated that there were so many complaints filed over this problem, and even an investigation was done, but it was not considered serious enough to be a recall. I can't even think about what would have happened if he had waited to pull over at the next exit or the first explosion had been bigger. Apparently, this is a problem with almost all years of this model since 2002. …
The fuel inlet seal on the top of the fuel tank had separated causing a smell of fuel and allowing matter to enter the fuel tank from the top...possibly causing the premature failing of the fuel pump. We understand GMC has extended the warranty on the vehicle for this issue to 150,000 miles. Our vehicle had over 155,000 miles when the problem occured but we never received notification from GMC of the extended warranty. Had we received this notification we would have taken in the vehicle for an immediate repair. The fuel pump failed and we had to purchase a new fuel tank (as a result of the faulty top seal) and fuel pump...costing us almost $1,700. We have a copy of the repair bill but I am unable to scan and upload it here at this time... I am in the military and will be moving to Korea in April, 2016
Vehicle has a inlet fuel leak, a known issue on the GMC Envoy XL 4x4, but has put a 150,000 mile cap on the recall which I find negligent as the issue still exist regardless of mileage, just seems like a way to worm out of responsibility.
The GMC Envoy xlt experiences a total loss of power under the following conditions. When the fuel tank is at or below a quarter tank of gas the vehicle's gas pedal becomes inoperable and the forward velocity is lost to the point that if you are in traffic the vehicle will immediately began to slow down resulting in a completely hazardous and unsafe situation where the driver has no choice but to pull off the road or be rear ended. This has occurred on several occasions only under the conditions described above. Several GMC Envoy xlt owners have expressed the same situation. This has been reported to GMC in 2005 but it appears that the problem is known but they aren't accepting responsibility as a manufacturer. Possible indicators May be the fuel pump assembly, fuel pressure regulator, or some other vital componet in the fuel system. I am sure GM knows.
NHTSA investigations
Fuel tank leak
In June 2007, GM will expand its special policy to address fuel tank inlet check valve (icv) fractures on certain model year (my) trailblazer ext and GMC envoy xl vehicles.the expanded policy covers my 2002-2004 trailblazer ext, GMC envoy xl, and GMC envoy xuv vehicles and will extend for a period of 10 years or 150,000 miles (whichever comes first).GM will provide free repair of the fuel tank.
Fuel pump module leaks gasoline
Odi has received reports that the fuel pump module leaks fuel and or vapor underneath the vehicle.GM states, the failure mechanism is corrosion of the fuel pump module flange which May lead to a fuel leak.corrosion of the fuel pump module flange is the result of the vehicle operating in a corrosive environment.odi has upgraded this pe to engineering analysis (ea07-009) to further assess this issue.
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 spillage during refueling
This investigation was opened on the model year (my) 2003 Chevrolet trailblazer.based on GM's information request (ir) response, odi added to its analysis the my 2003 GMC envoy and Oldsmobile bravada vehicles.these vehicles share the same vehicle platform (GM 360/370) and fuel fill components.incident summary numbers reported above include these vehicles.epa regulates the fuel dispensing rates at filling stations…
Fuel Level Gauge System Failure
The Office of Defects Investigation has received 668 complaints alleging inaccurate fuel gauge reading while driving in model year 2005-07 Chevrolet Trailblazer, GMC Envoy, Buick Rainier, and Saab 9-7x vehicles.Of the 668 complaints, 58 incidents were alleged to result in a vehicle stall.Of the 58 stalling incidents, 43 complaints reported stalling because the fuel level reading indicated more fuel availability than…
Frequently asked questions
Which GMC Envoy XL years have fuel system problems?
By NHTSA complaints, the 2006 (71), 2003 (63), 2004 (28) and 2002 (15) model years. Fuel System complaints make up 65% of all complaints for the 2006.
Is there a recall for GMC Envoy XL fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for any GMC Envoy XL model year. A widespread problem may still be covered by an extended warranty or a manufacturer service bulletin, so ask a dealer.
At what mileage do GMC Envoy XL fuel system problems start?
Across all years, half of the complaints with a recorded mileage happened before about 71,000 miles; 27% happened before 50,000 miles.
What part fails most often?
Owners most often name the storage › tank assembly (19 mentions), followed by the storage › tank assembly › filler pipe and cap (10).
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.