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
The fuel level sensor is malfunctioning giving me erroneous high and low readings. I noticed in August 2011, GM issued a special coverage for this exact problem, however it was only good for 10 years or 120,000 miles. My Envoy is 11-1/2 years old, but only has approx. 87,500 miles on it. Seeing this is an obviously safety issue which has LED to at least 1 known accident, I would like to know if there is anyway that you can help me get GM to extend the coverage to my Envoy? My Envoy also recently had a special coverage initiated for the headlamp driver module (hdm). I was able to get that fixed because GM issued the coverage for a total of 12 years and 150,000 miles. So the precedent has been set to provide coverage for a vehicle my age. Any help that you could provide would be appreciated. Thank you. [redacted]
My fuel gage suddenly stopped working on my 2007 GMC Envoy. It read that I had 1/4 tank left, so headed to the gas station on a city street. I turned the Envoy off, for about a 15 minute stop, and when I turned it back on, the gage said it was empty. I filled the tank, and it still said it was empty, and the light is on. About 25 miles later, the gage popped up to 1/4 tank , but quickly dropped back down to read as empty again. The light stays on now. All other gauges on the dashboard work properly. The check engine light also came on, and is still on. I made sure my gas cap was on properly, and it was. I just purchased this vehicle on 12-30-15, so I do not know if there were any previous issues . My 2007 Envoy had 61,061 miles on it when this occurred, on 3-4-16.
The contact owns a 2006 GMC Envoy. The contact stated that while driving at an undisclosed speed, the vehicle lost motive power. The failure occurred on three separate occasions. The vehicle was taken to an independent mechanic and diagnosed with fuel pump and fuel pump sensor failure. The fuel pump and fuel pump sensor needed to be replaced. The vehicle was not repaired. The manufacturer was not made aware of the failure. The failure mileage was 270,319.
At every fillup we can smell gas like there is a fuel leak. I had a shop do a fog test and they confirmed a leak "somewhere from the top of the tank". The tank would need to be dropped to visually inspect at a cost of $400-$500 just for the dropping of the tank. Then there would be added costs to repair whatever is causing the leak and smell of gas. After hearing that I came home to start my searching for recalls & safety notices to find that GM had a notice issued as well as the NHTSA, but it seems they cut the year off at 2004 & 120,000 miles. According to the thread below, it appears this was extended to vehicle under 150,000 miles which we are well under, but we don't have a 2002-2004 model. …
My accident was May 25th 2018, my back passenger went off of a soft shoulder throwing me into 2 trees, I hit first one and seatbelt came apart but still over one shoulder hitting second tree and only thing that saved me was my right foot was under the brake and not on it, I hit my head on windshield causing me to have vision problems, severe whiplash, and rsd in right leg, I have to have cane, walker, or powerchair, my husband wants a divorce bc of my depression, my kids get fustrasted bc I forget I said something and I continue to repeatedly say thing, I never had none of this wrong with me till this accident and monique hill in claims says none of my injuries nor my family problems have nothing to do with general motors and I didn't hit sensors, I never had a seatbelt on but if that was the case that ding sound wouldn't have stopped! …
Tl* the contact owned a 2005 GMC Envoy. While driving approximately 55 MPH, the driver was flagged down by another driver who noticed smoke underneath the front passenger side of the vehicle. The vehicle was pulled over to the side of the road and became engulfed in flames. The police, department of public safety, and fire department arrived at the scene. The fire department extinguished the fire. Both fire and police reports were filed. There were no injuries reported. The department of public safety diagnosed that the fire was started by a fractured fuel line. The dealer and manufacturer were not contacted. The vehicle was totaled and towed to a tow yard. The failure mileage was 132,000.
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.
Related recalls (1)
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 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 years have fuel system problems?
By NHTSA complaints, the 2005 (226), 2006 (207), 2003 (94), 2007 (87) and 2004 (67) model years. Fuel System complaints make up 46% of all complaints for the 2005.
Is there a recall for GMC Envoy fuel system problems?
Yes — 1 recall, including 02V-121 (hoses, lines/piping, and fittings, Aug 23, 2002). Recall repairs are free at authorized dealers; check a specific car with the VIN recall check.
At what mileage do GMC Envoy fuel system problems start?
Across all years, half of the complaints with a recorded mileage happened before about 76,000 miles; 23% happened before 50,000 miles.
What part fails most often?
Owners most often name the storage › fuel gauge system (34 mentions), followed by the storage › tank assembly (20).
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.