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 2002 GMC Envoy owners, lightly cleaned up (personal details are redacted by NHTSA).
My vehicle has developed a leak in the plastic fuel tank at the junction of the fill hose connection and the body of the tank that is causing release of flammable vapors and liquid gasoline underneath the vehicle and causing failure of emissions systems. These vehicles have a rampant and long-standing reputation for developing leaks in their plastic fuel tanks at this location which cannot be repaired by any normal means available to a consumer. Virtually all of these vehicles eventually develop leaks, which cause release of flammable fuel vapors and raw gasolene releases. Why isn't there a recall on these faulty fuel tanks? The manufacturer only provided a short-term solution for a limited period of time that is no longer available for vehicles that still have the leaking tanks. The condition is dangerous.
These vehicles have a rampant and long-standing reputation for developing leaks in their plastic fuel tanks. Virtually all of these vehicles eventually develop leaks, which cause release of flammable fuel vapors and raw gasolene releases. Why isn't there a recall on these faulty fuel tanks? The manufacturer only provided a short term solution for a limited period of time that is no longer available for vehicles that still have the leaking tanks. My vehicle now has a bad fuel tank leak that causes emissions test failure and leaks liquid gasolene. Surely a safety recall should be issued?
There are previously fixed recalls starting to pop up one at a time if they were fixed they wouldnt be back causing problems can someone check into this and let me know something I drive a 02 gmc envoy slt 4x4 4.2l. The mileage is unknown due to instrument cluster not working on the DIC settings.I purchased under the pretenses it only had 188000 miles but ive seen higher milage on some shop records also the Center console lid dont latch and other things I cant think of at the moment
Vehicle listed caught on fire while driving on interstate with unknown cause. No previous warnings. Was a risk to safety of driver/and or passengers.
I smelled a strong odor of gasoline while the vehicle was parked outside my residence. Performed a walk around inspection and found no visible signs of fuel leakage. Opened the hood and had no visible signs of leakage. Envoy is hard to start but once started continues to run with no issues. Gasoline fumes are evident in the cab while parked but disperse when moving down the road. Upon stopping in traffic, fumes immediately become very strong in the cab. Researching on line similar situations, it appears that there is a problem on top of the gas tank. Checked under the Envoy and noticed some minor streaking on the tank. I have stopped driving the vehicle until I can get the vehicle repaired. Assuming it is the same fuel pump erosion issue, the estimated cost to repair is between $650 and $900. …
I have notice my truck use more gas now and I'm smelling gas the gas reads low light comes on but I have gas in the truck took it to a shop and I was told all envoys have this issue and I need to contact this company if I'm in park the truck on or riding down the road the smell of gas is loud and the gas hand moves to empty then back to where it belongs I never notice gas on the drive way or ground but when the shop puttge truck in the air you could see the leak I have being reading so many reports on the same problems from envoys GMC vechiles on many internet sites this is my only vechile I'm on a fixed income this problem is on GMC
Tl* the contact owns a 2002 GMC Envoy. While driving the vehicle to the dealer at 60 MPH, the vehicle stalled without warning. The contact was able to coast the vehicle off the road. The vehicle failed to restart and was towed to the dealer where it was diagnosed that the fuel pump failed. The fuel pump was repaired and the contact was advised not to fill the tank above half. When the contact placed fuel in the vehicle, it leaked onto the ground. The manufacturer was notified of the failures. The approximate failure mileage was 141,000. Updated 04/21/2016
Tl* the contact owns a 2002 GMC Envoy. The contact stated that while operating the vehicle, an odor of fuel was present inside and outside of the vehicle. Also at times, fuel was seen on the pavement underneath the vehicle. The vehicle was taken to an independent mechanic who diagnosed the vehicle and stated that the fuel pump connection line was defective and needed to be replaced. The vehicle was not yet repaired. The local dealer and manufacturer were not notified of the failure. The failure mileage was 173,000. Invalid VIN.
Strong gasoline odor. Received a notice in 2016 regarding this. Notice said no action required if there was not gasoline smell. The odor was noticed about a month ago. Called the dealer that sent the notice who told me it expired! They never said the repair would expire, but to ignore it unless I smelled gasoline. So now gasoline fumes are not dangerous??
GM special coverage program, 14423 told repair part not available till May 2016 & is a hazard to drive. GM's solution to problem so that vehicle can be driven till May is to not fill fuel tank above one half. Refused due to vehicle hazard & personal safety. Vehicle remains at GMC dealership.
Related recalls
Fuel system, gasoline › Delivery › Hoses, lines/piping, and fittings
On certain sport utility vehicles, a fuel filter fitting can become disconnected. If this were to occur while attempting to start the engine, a no-start condition would result and fuel would be pumped out the fuel filter onto the ground.
Remedy: Dealers will replace the fuel filter quick connect retainers. Owner notification began September 20, 2002. Owners who take their vehicles to an authorized dealer on an agreed upon service date and do not receive the…
NHTSA investigations
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.
2002 trailblazer/envoy fuel tank leaks
See attached report.
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 years
Frequently asked questions
How common are fuel system problems on the 2002 GMC Envoy?
NHTSA has 56 complaints about the fuel & propulsion system of the 2002 GMC Envoy, 11% of the model year's 487 complaints. The component named most often is storage › tank assembly (7 mentions).
Is there a recall for 2002 GMC Envoy fuel system problems?
Yes — NHTSA recall 02V-121 (hoses, lines/piping, and fittings, Aug 23, 2002). Recall repairs are free at authorized dealers.
At what mileage do 2002 GMC Envoy fuel system problems start?
Half of the complaints with a recorded mileage happened before about 100,000 miles, and 13% before 25,000 miles.
Is it dangerous?
Owners linked 0 crashes, 1 fire and 0 injuries 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.