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 2003 GMC Envoy owners, lightly cleaned up (personal details are redacted by NHTSA).
The contact owns a 2003 GMC Envoy. The contact stated that while in drive(D), the vehicle shut off and then restarted. The message "Service Engine Soon" was displayed. The vehicle was taken to the local dealer, where it was diagnosed and determined that the instrument cluster needed to be replaced. The vehicle was repaired, but the failure reoccurred. The vehicle was taken back to the dealer who installed the original instrument cluster, but the failure persisted. The manufacturer was not notified of the failure. The approximate failure mileage was 98,000.
I noticed a electrical burning smell while driving on a side street. The engine made an unusual noise so I pulled over, turned the car off and put on the hazard lights. While waiting for the tow truck, the car started with no key in the ignition. The car ran for a short time then stopped and attempted to restart itself about 5 times. Our mechanic took a look at it and said there had been a fire in the fuse box. I took pictures of the charred remains of the fuse box, cover and connectors. Most of the plastic connectors under the fuse box could not be removed because they had melted and were fused onto the box. He noted the fire seemed to originate from fuse 46, the headlamp driver module. For the past few years, I had been experiencing headlight and tail light issues involving bulbs that were burning out frequently or were going out then coming back on.
Gradual coolant loss over time and no evidence of leak. This was due to a crack in the cylinder head that GM admitted to knowing about in TSB 06-06-01-019b on June 12, 2007). Coolant was slowly leaking into the oil, but was unnoticeable until it started to affect oil pressure from the oil becoming slushy and ruining the engine. This ended up resulting in resulted in the low engine oil light suddenly coming on and the car to stop running on a highway. The engine started steaming and the car was overheating. Mechanic is now saying the engine is in an unoperable shape due to driving with continued low oil pressure (no light had appeared until day of incident). GM had sent out a bulletin admitting to the issue but did nothing to notify their customers. They should immediately recall the affected vehicles and/or pay for a replacement. …
It started with engine misfiring causing engine to jolt which damaged #4 coil pack seal to failed allowing water intrusion. In 2008, the GMC mechanic replaced all six coils seals but in 2013-present p0440 engine code is a leak in the evaporative emission (EVAP). Loose fuel tank filler cap is the most common cause that triggers the p0440 code. I failed a few smog check spending hundreds of thousands of dollars yet my problem still existence. I've contacted the bureau of automotive repair because purrfect auto in fullerton,ca lied about fixing my car. The bar made purrfect auto replace the gas tank and gas cap yet the engine light is still on displaying code p0440. Its been 14 years and I'm still dealing with this problem.
Tl* the contact owns a 2003 GMC Envoy. The contact stated that a strong fuel odor emitted inside and outside of the vehicle continuously. Additionally, the engine warning indicator illuminated whenever the vehicle was in operation. The contact received notification of the manufacturer customer satisfaction program related to the fuel tank inlet valve replacement. The remedy part needed to perform the repair was unavailable. The contact stated that the manufacturer exceeded a reasonable amount of time for the repair. The manufacturer was notified of the failure. On November 23, 2015. The failure mileage was 119,292. Updated 07/05/16
My 2003 GMC Envoy just turns off at any given moment. Out of no where, while driving, waiting at a red light or stopped at a stop sign my car just shuts down/turns off. It's been doing this for years. Very dangerous and unsafe. Secondly the "service engine soon" light on my 2003 GMC remains on. Took it into been serviced by the GMC dealer service department and they couldn't figure out the problem. Now I cannot get my car to pass inspection nor get it register. This is a major problem.
Tl* the contact owned a 2003 GMC Envoy. The contact stated that while driving 30 MPH, the engine compartment engulfed into flames without warning. The fire department was notified and no injuries were reported. The vehicle was not taken to the dealer. The manufacturer was made aware of the failure and did not offer any assistance. The VIN was not available. The vehicle was declared destroyed. The failure and current mileages were 79,000.
Tl* the contact owns a 2003 GMC Envoy. While operating the vehicle, the service engine light illuminated. While in four wheel drive mode, the vehicle would not accelerate. The vehicle was taken to the dealer where it was diagnosed that the icv was faulty and needed to be replaced. The vehicle was not repaired. The manufacturer was not notified of the failure. The failure mileage was 150,000.
Dt: the contact stated while driving, the reduce power engine and oil pressure low, check engine ights illuminated. The vehicle stopped, although, the enginewas still running. The dealership was unable to diagnose a problem, but replaced the tank gasket, gas pedal, and computer chip. This caused the contact to rear end another vehicle.
Check engine light illuminated on instrument cluster. Diagnostics indicated a code po 442. This code is indicative of a fuel system leak in the evaporative emission system. Replaced gas cap. Problem not resolved. Filled vehicle with gasoline in October 2010 and several times since. Strong odor of gasoline is present. Each time fuel nozzle fails to shut off fuel from gasoline pump and gasoline is spilled on the ground near driver side rear door creating an environmental and major safety hazard. Vehicle never in accident or modified in any way. Vehicle has 62,000 miles. A courtesy general motors repair program is in place for these vehicles if the long wheelbase models. Numerous occurrences in the short wheelbase models also. …
Engine complaints in other Envoy years
Frequently asked questions
How common are engine problems on the 2003 GMC Envoy?
NHTSA has 35 complaints about the engine & cooling of the 2003 GMC Envoy, 9% of the model year's 394 complaints. The component named most often is engine (10 mentions).
Is there a recall for 2003 GMC Envoy engine problems?
No. NHTSA lists no engine & cooling recall for the 2003 GMC Envoy, though it has 7 recalls 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 2003 GMC Envoy engine problems start?
Half of the complaints with a recorded mileage happened before about 62,000 miles, and 26% before 25,000 miles.
Is it dangerous?
Owners linked 1 crash, 2 fires and 0 injuries 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.