2002 GMC Envoy Fuel system Problems

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.

NHTSA ID

11748101

Incident

Jul 3, 2025

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.

NHTSA ID

11700025

Incident

Sep 17, 2025

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?

NHTSA ID

11699610

Incident

Sep 17, 2025

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

NHTSA ID

11515298

Incident

Apr 19, 2021

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.

NHTSA ID

11350027

Incident

Aug 10, 2020

Mileage

173,000 mi

I AM SMELLING FUEL IN AND AROUND THE TRUCK WITH NO VISUAL SIGNS OF FUEL ON THE GROUND.

NHTSA ID

11291702

Incident

Dec 28, 2019

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??

NHTSA ID

11092869

Incident

Apr 16, 2018

Mileage

230,000 mi

SMELL GAS IN AND OUT SIDE OF VEHICLE. FUEL LEAKING FROM THE GAS TANK DUE TO RUSTED LINES.

NHTSA ID

10899260

Incident

Aug 19, 2016

Mileage

179,000 mi

WHILE IN MOTION ONLY, A ENGINE LIGHT ACCOMPANIED BY A REDUCED ENGINE POWER ENGAGES MAKING THE VEHICLE UNMANAGEABLE TO RESPONSE AND CAUSE THE VEHICLE TO STALL.

NHTSA ID

10901949

Incident

Aug 26, 2016

Mileage

40 mi

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

NHTSA ID

10887606

Incident

Feb 18, 2016

Mileage

10 mi

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*LJ *TR

NHTSA ID

10839924

Incident

Jan 25, 2016

Mileage

141,000 mi

FUEL IS LEAKING OUT THE TOP OF TANK SOMEWHERE. CAN'T SEE EXACTLY WHEE WHILE RUNNING. DOESN'T RUN OUT WHEN VEHICLE IF NOT RUNNING.

NHTSA ID

10838767

Incident

Feb 24, 2016

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.

NHTSA ID

10821834

Incident

Jan 18, 2016

Mileage

69,950 mi

VEHICLE LOSES POWER DRASTICALLY WHEN GOING UP ANY INCLINE. WAS GOING 65 AND SPEED DROPPED TO 35 GOING UP SLIGHT GRADE HILL.

NHTSA ID

10763342

Incident

Sep 12, 2015

Mileage

151,000 mi

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. MA 10/6 THE CONSUMER STATED AFTER REMOVING THE GAS TANK, HE ATTEMPTED TO REMOVE THE FUEL LINES FROM THE FUEL PUMP. THE METAL LINES BROKE OFF AT THE TOP OF THE FUEL PUMP AS HE ATTEMPTED TO REMOVE THE CLIPS HOLDING THE LINES ON TO THE FUEL PUMP. THE TOP OF THE FUEL PUMP AND THE ASSOCIATED METAL LINE WERE RUSTED BEYOND REPAIR. IT APPEARED THE METAL LINES AS PART OF THE FUEL PUMP WERE SPRAYING FUEL ON THE TOP OF THE FUEL TANK WHEN THE PUMP WAS RUNNING. THE DESIGN OF THE TOP OF THE TANK WITH THE FUEL PUMP PROVIDED A BOWL ON THE TOP OF THE TANK WHERE THE FUEL PUMP WAS LOCATED ALLOWING SALT WATER TO POOL ON TOP OF THE TANK DURING THE WINTER DRIVING SEASON. THE FUEL PUMP WAS REPLACED AND THE TANK WAS RE-INSTALLED. UPDATED 03/01/16.*JB

NHTSA ID

10746903

Incident

Aug 1, 2015

Mileage

101,250 mi

I COULD SMELL GAS AND MY SON A MECHANIC LOOKED AT IT AND SAID IT IS LEAKING ON THE TWO LINES THAT COME OUT THE TOP OF THE FUEL PUMP.

NHTSA ID

10715471

Incident

Feb 26, 2015

Mileage

200 mi

IT LIKE IT NOT GETING ANY GAS WHEN I HIT THE GAS IN BOGGS DOWN LET OFF OTS FINE PCM IM GUESS. *TR

NHTSA ID

10546123

Incident

Sep 5, 2012

I STARTED SMELLING GAS SEVERAL WEEKS AGO. NOW I CAN SEE SOME GAS ON MY DRIVEWAY NEAR WHERE THE FUEL TANK IS LOCATED. I'M AFRAID OF A FIRE. *TR

NHTSA ID

10519766

Incident

May 10, 2013

Mileage

74,700 mi

EVERYTHING STARTED APRIL LAST YEAR AND ITS ONE THING AFTER ANOTHER SINCE. FIRST MY ENGINE STARTED STALLING, WHILE DRIVING. ONE INCIDENT, I LOST HALF A TANK OF GAS WITHIN A 15 MINUTE RIDE, WHICH I HAVE A 17 GALLON TANK. THEN WHILE DRIVING ON AN EXPRESSWAY, IT SUDDENLY DROPPED FROM 70 TO 20 BEFORE I COULD GET OVER TWO LANES TO GET OUT OF THE WAY OF TRAFFIC. IVE CLEANED THE THROTTLE BODY, IVE CLEANED THE CAMSHAFT ACTUATOR, IVE REPLACED THE AIR FILTER, FUEL FILTER, AND THE OIL TWICE WITHIN A 8 MONTH PERIOD, AND YET IT STILL CONTINUES TO STALL. NOW I RECENTLY CHANGE THE WATER PUMP TO SEE IF THAT WOULD HELP, EVEN THOUGH MY CAR WAS NOT OVER HEATING, NOW ITS STALLING EVEN WORSE; I CANT EVEN MAKE IT THROUGH A DRIVE THROUGH WITHOUT HAVING TO START IT TWICE. SECOND AND EVEN SCARRIER ISSUE, I HIT POT HOLE ONE DAY AND BEFORE I COULD MAKE 15 MILES, I HEARD GRINDING. A CV JOINT HAD TO BE REPLACED, THEN TWO DAYS AFTER THAT THE OTHER CV JOINT BROKE OFF AND BROKE MY FRONT AXLE DISCONNECT ASSEMBLY. DID I HIT ANYBODY? NO THANK GOD I WAS IN THE RIGHT HAND LANE AND COULD GET OVER WITHOUT HITTING ANYONE OR CAUSING INJURY TO MYSELF. IVE REPLACED BOTH CV JOINTS AND THE ASSEMBLY NOW AND EVEN DID THE STRUTS WHILE I WAS AT IT, BUT HAVE ALSO BEEN TOLD I NEED CONTROL ARMS NOW. AND STILL MY CAR IS STALLING, GRINDING WHEN I TURN AND I CANT GET THE CHECK ENGINE LIGHT TO CLEAR LONG ENOUGH TO GET IT INSPECTED. MY DRIVERS SIDE WINDSHIELD WORKS WHEN IT WANTS TO AND NOW THE CAR IS STARTING TO VIBRATE UNBELIEVABLY. IVE KEPT MY OIL CHANGED, IVE KEPT MY FILTERS CHANGED, IVE NEVER TAKEN THIS THING OFF ROAD AND HAVE HAD IT OVER 7 YEARS AND JUST IN THE LAST YEAR I HAVE DUMPED MORE MONEY IN THIS CAR THAN I HAVE SINCE IVE OWNED IT. *TR

NHTSA ID

10510727

Incident

Apr 2, 2012

Mileage

165,000 mi

AT FUEL STATION, WITH A QUARTER TANK OF FUEL IN VEHICLE, THE NEW GAS OVERFLOWED OUT OF THE TANK FOR NO APPARENT REASON, RUNNING DOWN SIDE OF VEHICLE ONTO GROUND. NOT ABLE TO FILL TANK. *TR

NHTSA ID

10499897

Incident

Feb 25, 2013

Mileage

190,000 mi

TL* THE CONTACT OWNS A 2002 GMC ENVOY. THE CONTACT WAS DRIVING APPROXIMATELY 10 MPH WHEN FUEL BEGAN TO SPRAY OUT OF THE FUEL TANK AND ONTO THE GROUND. THE VEHICLE WAS TAKEN TO AN AUTHORIZED DEALER FOR DIAGNOSIS. THE TECHNICIAN STATED THAT THE FUEL PUMP MODULE RETAINER WOULD NEED TO BE REPLACED. THERE WAS A RECALL ASSOCIATED WITH THE FAILURE UNDER NHTSA CAMPAIGN ID NUMBER 02V121000 (FUEL SYSTEM, GASOLINE: DELIVERY: HOSES, LINES/PIPING, AND FITTINGS). THE CONTACT'S VIN WAS INCLUDED IN THE RECALL HOWEVER, THE CONTACT WAS ADVISED THAT THE RECALL WAS EXPIRED. THE MANUFACTURER WAS NOTIFIED OF THE PROBLEM. THE APPROXIMATE FAILURE MILEAGE WAS 100,000. THE VIN WAS UNAVAILABLE.

NHTSA ID

10486532

Incident

Jan 5, 2012

Mileage

100,000 mi

IT BEGAN WITH A GAS SMELL FOR SEVERAL WEEKS WITH NO WET AREAS OR DRIPS. NOW THEIR APPEARS TO BE A LEAK FROM THE GAS TANK OR FILLER TUBE AND IT HAS BECOME MORE SEVERE. *TR

NHTSA ID

10483514

Incident

Jul 9, 2012

Mileage

148,000 mi

IN FEBRUARY OF 2012 I BEGAN TO NOTICE A VERY LARGE ODOR OF GASOLINE COMING FROM THE REAR OF THE VEHICLE. I HAVE OWNED THIS CAR SINCE SEPTEMBER OF 2009 AND THIS HAS JUST BECOME AND ISSUE. LOOKED UP VEHICLE RECALLS AND CAME ACROSS THIS. SUMMARY: 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. CONSEQUENCE: IF THE FITTING BECOMES DISCONNECTED WHILE THE VEHICLE IS IN MOTION, THE ENGINE WOULD STOP DUE TO INADEQUATE FUEL SUPPLY AND CAUSE A LOSS OF POWER STEERING ASSIST. IF AN IGNITION SOURCE WERE PRESENT, FUEL LEAKAGE FROM A DISCONNECTED FUEL FILTER FITTING COULD RESULT IN A FIRE. ACTIONS: 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 FREE REMEDY WITHIN A REASONABLE TIME SHOULD CONTACT CHEVROLET AT 1-800-222-1020. GMC AT 1-800-462-8782, OR OLDSMOBILE AT 1-800-442-6537. FOR DETAILED INFORMATION & SUPPORTING DOCUMENTS, SEE THE OFFICIAL NHTSA PAGE CONCERNING RECALL #02V121000 GM SAID MY CAR WAS NOT ELIGABLE FOR REPAIR.

NHTSA ID

10453434

Incident

Jan 1, 2012

Mileage

119,217 mi

TL* THE CONTACT OWNS A 2002 GMC ENVOY. THE CONTACT STATED THAT THE VEHICLE STALLED DUE TO THE FUEL LEVEL GAUGE DISPLAYING INACCURATE FUEL LEVELS. THE FUEL LEVEL GAUGE DISPLAYED THAT THE FUEL TANK WAS FULL WHEN IN FACT, THE TANK WAS EMPTY. THE FAILURE RECURRED THREE TO FOUR TIMES AND THE VEHICLE WAS TAKEN TO A LOCAL REPAIR SHOP WHERE THE CONTACT WAS INFORMED THAT THE FUEL GAUGE WOULD NEED TO BE REPLACED. THE VEHICLE WAS NOT REPAIRED. THE CURRENT MILEAGE WAS APPROXIMATELY 105,000 AND THE FAILURE MILEAGE WAS APPROXIMATELY 95,000.

NHTSA ID

10398482

Incident

Jul 23, 2010

Mileage

95,000 mi

2002 GMC ENVOY - CONTINUE TO EXPERIENCE FUEL SMELL CONDITION. HAD VEHICLE SERVICED IN 2009 FOR THIS ISSUE. DEALER REPAIRED PER RECALL, NEVER NOTIFIED OF THIS ISSUE, A FUEL FILLER NECK ISSUE THAT ALLOWED VAPORS TO ESCAPE. PROBLEM HAS RESURFACED AND IT IS SUSPECT THAT ISSUE IS FUEL TANK RELATED. ISSUE IS DIFFICULT TO IDENTIFY WITHOUT SIZABLE EXPENSE. NOT SURE NOW IS ISSUE IS REPEAT OF REPAIRED CONDITION OR FUEL TANK PROBLEM. THIS IS A SERIOUS ISSUE WITH WARNING ABOUT FUEL VAPORS AND CONCERN ABOUT FIRE AND EXPLOSIONS IN AROUND GAS STATIONS YET THIS KNOW CONDITION IS ALLOWED TO EXIST ON THESE GM VEHICLES WITHOUT A SAFETY RECALL. *TR

NHTSA ID

10376759

Incident

Jan 14, 2011

Mileage

90,000 mi