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 Xuv owners, lightly cleaned up (personal details are redacted by NHTSA).
About 9-10 months ago started noticing a fuel smell around back of truck. Replaced gas cap, but the odor continued. Inquired at local dealer, but was told they could not determine the cause. Tried a local mechanic that I had used before, but at that time, they claimed they found no cause either. On my third trip to local mechanic, was informed that there is a crack in my filler/gas tank causing the smell. Finally they found the cause only to inform me that now my truck is beyond the mileage and/or date of the 'recall' that I was never informed about by GMC about my gas tank, and it will only cost "about" $1200 to replace my gas tank. I've resided in the same home well longer than I've owned my truck, so my home address, phone number and email are all still the same as they were then, and had no notification that their was any type of recall on my truck. …
Started smelling gas, started dripping fuel. After investigating the fuel lines coming out of the fuel pump were severely corroded at the top of the gas tank. Dripping gas could have caught fire. Learned there was a TSB on this and extended warrenty due to corrosion of fuel lines. The warrenty was for 10 years or 150K. The vehicle is now 11 years old. I have lived in the same house for eight years and never received a recall or TSB notice from GMC. Over 800$ for a new fuel pump and to drop gas tank for repairs. While the vehicle is a 2004 it only has 67K on it.
I was doing a rear brake job and smelled gasoline, so I went under the vehicle and observed there was a wet spot on the rear of the fuel tank. Upon closer examination I found the inlet part of the fuel tank was broken and allowing fuel to exit the tank, can we say fire risk, so I went online to try to purchase a replacement tank and I found where several people had had this sameproblem, but no recall is in place ?????
Tl* the contact owns a 2004 GMC Envoy Xuv. While driving, the contact smelled fuel. The vehicle was taken to an independent mechanic who stated that the fuel pump was corroded and the odor was a result of a fuel leak. The vehicle was not repaired. The manufacturer was notified of the failure. The approximate failure mileage was 116,000.
Smell of gas inside of vehicle, check engine light on and notice of gas on garage floor. Took vehicle to a mechanic and found out that the gas tank was leaking around the neck of the tank where the refill hose connects. Found out that Chevrolet and GMC had a special coverage adjustment # 07099a on this problem. I took my vehicle to the dealer and I was told that my vehicle is not covered on this sca because of the VIN number. I called GMC customer service on recalls and I was told the same thing. The dealer agreed to pay 2/3's of the bill and I will have to pay 1/3 of it. On the sca sheet it list the following for my vehicle. The last 8 digits of the VIN starting with 46100001 to 46116824. My vehicle is leaking so badly that I can smell gas inside of the vehicle all the time. It is very dangerous to drive. Also I park my vehicle in my garage all the time and this is dangerous. …
I purchased a 2004 GMC Envoy Xuv and have several significant problems with this vehicle. After researching it seem others have had the same troubles. Since we owned the vehicle, the rear window is found down and noone was even in/near the vehicle. It continues to work but still will go down by itself. A year ago I had to replace the fuel tank, this was right after we took it in for inspection on a recall of smelling gas fumes while driving and possible corrosion in fuel lines. Of course the fuel lines were not corroded so we were told. I footed the bill $800+ to get a new fuel tank ,as neck on tank was cracked and was told that this is why we smelled gas. Luckily, I went to my garage and saved several hundred dollars from the dealers cost to repair. Last weekend 9/10/10 my family was driving to town and the middle window unexpectedly dropped and now does not work. …
After refueling the vehicle, a strong odor of gasoline was present and the "service vehicle soon" light was lit. Using the on-star vehicle diagnostic service, the diagnostic code indicated a fuel system leak or loose gas cap. However, upon inspecting the vehicle it was found that the fuel tank inlet check valve, which is part of the fuel tank, was fractured and leaking fuel. In checking with GMC, there was an existing NHTSA action number: pe07014 concerning this defect for my make/model/year vehicle. A GMC special coverage policy extension (07099a) was also in effect since 2007 for 10 years or 150,000 miles to effectively repair this known fuel tank defect. This repair involves a complete replacement of the fuel tank. However, GMC refused to replace the fuel tank and cover the cost of repair because my VIN number was not in the listed range. …
I have a 2004 SUV xlt. I bought my car with 400 miles on it. I had the gas tank replaced early on. Went back to GMC b/c they had not installed it properly. I've had both front and rear sway bars replaced and both knock sensors replaced. My middle window decided to quit working and I haven't gotten it fixed because the guys at the GMC service center said they couldn't imagine what it could be and they would have to charge me $100 for a diagnosis!! My radio/cd player is only half lit up and stops working when it gets too hot from playing a cd... I am currently having issues with the fan clutch, thermostat and a leak in my front differential. Meanwhile the guys at the dealership wanted to charge me $1,500 to replace my knock sensors again and didn't even find the leak when they were "diagnosing" my issue. …
Bought new and loved the ride.list price was over $42,000. Well maintained. 1st lost speedometer and other gauges. Replaced instrument cluster. 40K miles replaced blower motor. 60K miles window behind backseat just dropped. Replaced regulator (I think). 62K miles check engine light - replaced fuel cap then took to dealer - $600 replaced a oxygen sensors. Check engine light came back on a few days later with same code. Just driving with it now. 68K miles - replaced power steering pump.89K miles - driver side power window module burnt - replaced. 91K miles - while replacing driver side headlight found wire to light was melted. 98K miles rear speakers quite working. Probably a couple of things I have forgotten. 8-12-14 it has 99360 miles on it and still love the ride but have lost faith in GM. …
My speedometer has stopped working. The gas gauge says empty when I have just fueled the car to full. The car will surge forward when I am backing out of the drive way and putting car in drive. I have to immediately press on the brake and return the car to neutral position to stop from running into parked cars or the curb. Tonight we were leaving the park and both headlights ( low beam) are not working. All other lights and flashers on the car work. The interior light on the left half of the A/C controller does not work.the motor in the rear window went out. The dealership charged me $ 1000 to replace the motor and then they advised me that the middle window motor was bad and that would be an additional $600 to repair. I only could afford the back window motor. This car is my only mode of transportation and I cannot believe that GM has npt placed a recall on all of these issues.
Fuel System complaints in other Envoy Xuv years
Frequently asked questions
How common are fuel system problems on the 2004 GMC Envoy Xuv?
NHTSA has 29 complaints about the fuel & propulsion system of the 2004 GMC Envoy Xuv, 19% of the model year's 150 complaints. The component named most often is storage › tank assembly › mounting (1 mentions).
Is there a recall for 2004 GMC Envoy Xuv fuel system problems?
No. NHTSA lists no fuel & propulsion system recall for the 2004 GMC Envoy Xuv. 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 Xuv fuel system problems start?
Half of the complaints with a recorded mileage happened before about 82,000 miles, and 4% before 25,000 miles.
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.