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Fuel systemPart report

2004 GMC Envoy XL Fuel system Problems

Complaints
28about this part
Share
15%of 187 total for the year
Median mileage
101,000miles
Trend
StableComplaints filed in the last 3 full calendar years are within 25% of the 3 years before.

NHTSA recorded 28 complaints about the fuel system of the 2004 GMC Envoy XL, 15% of the 187 complaints for this model year. Where a mileage was given, the median is 101,000 miles. 1 a fire, according to the filers.

Example complaints

Selected from NHTSA records; personal details are removed. They are consumer reports, not findings.

“My Gmc's service engine soon light went on and I took into the shop. They stated that there is a fuel issue for the fuel cap and that the fuel tank needs to be replaced because it leaks. This is a manufacturers defect and this part should never wear out over time or due to the number of miles driven. Gmc needs to stand behind their vehicle and replace this part for free!”

NHTSA complaint #10526242, filed 2013-07, 160,021 miles

“Own a 2004 Gmc envoy and I have problems with the fuel gauge and the odometer. The fuel gauge goes past the f line when the vehicle is not on fuel. Also the odometer will stop working or get stuck on 10-15 MPH. He happens often...every other day. I was told that it would cost 1400 to fix and a possibility it may not fix the problem.”

NHTSA complaint #10405702, filed 2011-06, 95,000 miles

“I was driving and my vehicle on I-985 hall county ga. My check gage light came on and less than 1/2 of a mile it start to smoke and burn as soon as I stopped turned of the ignition. It burnt to the ground from the engine area to the inside.”

NHTSA complaint #10888197, filed 2016-07, 160,000 miles

“My envoy has had the check engine light on for years, and the smell of gas, went to Gmc and they said need new gas cap, didn,t work, went to another car repair need new gas cap, same thing over and over again, every month on my onstar report, said I had emission problems, they tested the car, looks like it could be you need a new gas cap..... A few months ago my Gmc would not start, call aaa to pick up envoy and take in the charles shop near my home.... …”

NHTSA complaint #10478183, filed 2012-10, 39,000 miles

“Special coverage adjustment fuel tank inlet check valve fracture #07099a. Issued august 24, 2007. My 2004 Gmc envoy is now experiencing this problem. I was never notified of this as GM claims they did not know I was the owner of this car. I bought it used in 2005. I was told by a mechanic when I took it in to check out the problem that I should not fill the gas tank full as it could cause gas leakage. I am also facing an expensive bill to get this fixed. A recall was never issued and it appears this is a life safety issue. I would appreciate your attention in this matter.”

NHTSA complaint #10573049, filed 2014-03, 133,260 miles

Related service bulletins

Fuel system: other model years

YearComplaintsShare of year
20067165%
20042815%
20036328%
20021521%

Other parts of the 2004 GMC Envoy XL

Electrical system
81 complaintsTransmission and drivetrain
20 complaintsEngine cooling
15 complaintsExterior lighting
11 complaintsVisibility (wipers, defrost, mirrors)
10 complaintsVehicle speed control
9 complaintsAir bags
7 complaintsBrakes
6 complaintsEngine
5 complaintsEquipment
5 complaintsBody and structure
5 complaintsTires
5 complaints

← All problems reported for the 2004 GMC Envoy XL

About this data. Data from NHTSA (ODI) complaints, recalls, TSBs and investigations, updated Oct 31, 2026. Complaints are unverified consumer reports and may be duplicated or inaccurate.

To check a specific vehicle for open recalls, use its VIN at nhtsa.gov/recalls. Methodology