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 2004 GMC Envoy owners, lightly cleaned up (personal details are redacted by NHTSA).
The contact owned a 2004 GMC Envoy. The contact stated that while driving at an undisclosed speed, the vehicle was shaking and made an abnormal rattling sound before the vehicle lost motive power and stalled. The vehicle was restarted and driven to the dealer to be diagnosed. The contact was informed that the engine needed to be replaced. The vehicle was not repaired. The manufacturer was made aware of the failure, and a case was filed. The failure mileage was approximately 130,000. The VIN was unavailable.
Vehicle was being driven on a two way highway at approximately 55 MPH. Vehicle lost engine power while driving and the gas pedal lost resistance and went to the floor. Vehicle was steered over to the side of the road. While the vehicle was steered over to the side of the road, check engine and other dash lights started flashing chaotically. White smoke started coming from under the hood. Within a short time, white smoke turned into black smoke and then flames started to appears. The fire under the hood eventually continued to grow until it completely burned the engine compartment most of the first two rows of the interior before the firemen arrived and were able to put out the fire.
Vehicle was being driving approximately at 55 MPH. Engine loss power, gas pedal lost resistance and went all the way down to the floor board. Vehicle was pulled over to the side of the road and engine was stalled and all the dash lights were flashing one and off. Engine started to have white smoke coming from under the hood. After a few minutes, the white smoke turned into black smoke and the engine caught on fire. Vehicle was engulfed in flames after a few minutes.
Tl* the contact owned a 2004 GMC Envoy. While driving approximately 55 MPH, white smoke emerged from the engine compartment. The contact had to pull over in a parking area and exited the vehicle. The vehicle burned to the ground. The police and fire department were present. The vehicle was towed to the contact's residence. There were no injuries. The manufacturer was not notified of the failure. The vehicle was destroyed. The approximate failure mileage was 100,000.
Tl contact owns a 2004 GMC Envoy. While driving approximately 45 MPH on normal road conditions, the contact rear-ended the preceding vehicle. There were no damages to the vehicles or the occupants. He pulled over to the side of the road and noticed smoke suddenly appearing from the front end of the vehicle. Immediately, the passenger compartment became engulfed in flames. The contact safely exited the vehicle. The police and fire departments were called to the scene and a report was filed. The vehicle was completely destroyed and towed to a collision center. The insurance company was notified; however, the cause of the failure has not yet been determined. The VIN was unknown. The failure and current mileages were 75,000.
I just had my brakes serviced and my bushings changed, but my ABS light still comes on. Also when I go to brake the car starts to shake and I'm going the speed limit. The engine has a rough idle, and shuts off when at a complete stop and when the vehicle is in motion. I've had many things replaced on the vehicle, such as purge valve, gas cap. Charcoal canister and fuel tank. In the engine the spark plugs were changed as well as the coil packs and the fuel injectors. Along with the camshaft sensor. Still getting p0455 and po0014. Won't pass smog can't register vehicle, but my only means of transportation. 2004 GMC Envoy xuv slt 4dr 2wd
fraudulent emissions certificate fraudulent mileage fraudulent vin EMISSIONS CERTIFICATE matching an out of state TEXAS vin [redacted] CALIFORNIA [redacted] . FRAUDULENT DEALER SALE. FRAUDULENT DMV CALIFORNIA REGISTRATION AND TITLE TRANSFER. LIQUIDS GASES ODORS FUMES EMITTING FROM VEHICLE [redacted] HAVE ILLLEGAL TRANSFER OF TITLE TO MYSELF FROM DEALER AND ILLEGAL TRANSFER OF FRAUDED REGISTRATION FROM DEALER. AND BELIEVE VIN IS NOT ACCURATE ACCORDING TO VEHICLE NOR BARCODE OR OTHER COMPONENTS
Tl contact owns a 2004 GMC Envoy. While driving 55 MPH, the contact noticed smoke coming from the rear of the vehicle. She pulled over to inspect the vehicle and noticed that the front end was engulfed in flames. An investigator from her insurance company concluded that the fire derived from the engine compartment. A fire report was filed. The vehicle was completely destroyed. The contact has pictures of the vehicle after the failure. The manufacturer provided no assistance. The failure and current mileages were 47,970. Updated 07/15/08 updated 07/15/08
Tl* the contact owns a 2004 GMC Envoy. While the vehicle was stationary, the exhaust manifold fractured and the heat from the exhaust manifold damaged the frame of the vehicle. The contact stated that the failure caused severe rust and corrosion. In addition, the contact stated that there were holes in the frame. A dealer was not made aware of the failure. The manufacturer stated that the failure was not safety related and there were no recalls on the vehicle. The failure mileage was 136,000.
While driving another motorist saw smoke coming from rear of vehicle and got vehicle stopped on side of road at which time the engine compartment was engulfed in flames. Called fire dept and police. Fire spread through the hearer box into the vehicle and across dash until it began burning the headliner. Fire dept put out fire but was a total loss. There was no indication on instrument panel of any problems (all gauges showing normal readings).
Engine complaints in other Envoy years
Frequently asked questions
How common are engine problems on the 2004 GMC Envoy?
NHTSA has 35 complaints about the engine & cooling of the 2004 GMC Envoy, 10% of the model year's 367 complaints. The component named most often is engine (4 mentions).
Is there a recall for 2004 GMC Envoy engine problems?
No. NHTSA lists no engine & cooling recall for the 2004 GMC Envoy, 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 engine problems start?
Half of the complaints with a recorded mileage happened before about 78,000 miles, and 10% before 25,000 miles.
Is it dangerous?
Owners linked 1 crash, 6 fires and 1 injury 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.