Engine Exhaust System Problems of GMC Envoy

GMC Envoy owners have reported 18 problems related to engine exhaust system (under the engine and engine cooling category). The most recently reported issues are listed below.

1 Engine Exhaust System problem of the 2006 GMC Envoy

Failure Date: 03/19/2012

My GMC Envoy denali 2006 uses up to 2 to 3 quarts of oil in a 30 day period. I have no leaks or exhaust problems. It finally collapsed a lifter and push rod. Says there is no notice or recall, but the is the same engine they used in the 2003 pontiac, they did recall those motors. Does any one have some help for me?.

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2 Engine Exhaust System problem of the 2005 GMC Envoy

Failure Date: 07/25/2011

Exhaust manifold failure. Mechanic says in 25 years he has never seen as many failures as in these models,as it is usualy very rare for them to fail. In researching on line I have found it is a common problem in '03 through '08 model GMC Envoys and chevy trailblazers.

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3 Engine Exhaust System problem of the 2008 GMC Envoy

Failure Date: 09/17/2010

2008 GMC Envoy 51,000 miles exhaust manifold cracked I had it replaced and was told by dealer a 3 day wait would be necessary as they had used stock parts on another Envoy with same problem . Advised me not to drive because it may catch fire.

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4 Engine Exhaust System problem of the 2008 GMC Envoy

Failure Date: 08/05/2010

Bought the vehicle last November from georgian pontiac Buick GMC in barrie ontario canada last November 2009. Learned I had a cracked exhaust manifold on my 2008 Envoy at 87 000 km. It has not yet been repaired. Research is ongoing.

5 Engine Exhaust System problem of the 2005 GMC Envoy

Failure Date: 07/26/2010

Broken manifold bolts which it appears from searching the internet is a common problem on GMC v-8 engines.

6 Engine Exhaust System problem of the 2004 GMC Envoy

Failure Date: 07/24/2010

I have a 2004 Envoy xuv with a cracked exhaust manifold. My mechanic said he has seen a lot of these on the 4. 2 and tells me it is due to bad design. GMC won't fix it unless I give them about $1,000. 00. Exhaust manifolds almost never cracked in the past. Please insist they help us like we helped them.

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7 Engine Exhaust System problem of the 2004 GMC Envoy

Failure Date: 07/16/2010

2004 GMC Envoy 4. 2 liter engine - defective exhaust manifold. Noticed casting crack at 81,000 miles replaced complete manifold, 02 sensor, gaskets at 89,000 miles. According to dealer no recall or extended warranty on this part that many others have had crack.

8 Engine Exhaust System problem of the 2004 GMC Envoy

Failure Date: 05/15/2010

I heard a clicking noise from under the hood and after pulling off the cover plate for the engine exhaust manifold I saw the manifold was cracked. At idle speed fumes get inside vehicle. Repair has not been made so old part is available. Upon research on the internet there are numerous other complaints of this problem. I sent an e-mail to gm and someone called and said they need more people to report it to get something done. I believe it is a safety issue because of the fumes and possible fire hazard.

9 Engine Exhaust System problem of the 2003 GMC Envoy

Failure Date: 02/28/2010

No events led up to failure. Exhaust manifold is cracked and leaking. GMC Envoy xl slt 6 liter. Have not yet received new part. Will be replacing this week.

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10 Engine Exhaust System problem of the 2003 GMC Envoy

Failure Date: 02/23/2010

Throat of gas tank leaking on a 2003 Envoy. Reviewing internet, found many similar problems on the Envoy's and stated in 2007 that NHTSA was investigating. Mechanic stated very unusual to leak in that spot. Also, have replaced both head light sockets due to burning up. Have talked to many Envoy owners with the same problem. When bulb burns out and the recommended bulb is put in place the socket and wiring gets so hot that the socket is charred and is no longer functional. Wires have to be cut and a new socket wired in.

11 Engine Exhaust System problem of the 2004 GMC Envoy

Failure Date: 01/08/2010

Speedometer does not work accurately. Check engine light came on randomly. Is currently out and I was able to pass emissions, hopefully it will remain out. Had to replace many parts including the heater core, thermostat and coolant. Now I am experiencing a problem with the fan of the car.

12 Engine Exhaust System problem of the 2005 GMC Envoy

Failure Date: 12/29/2009

The exhaust manifold on my 2005 GMC Envoy xl slt is cracked. I have researched and discovered many of these GMC Envoy and chevy trailblazers have this same incident occurring.

13 Engine Exhaust System problem of the 2004 GMC Envoy

Failure Date: 07/07/2009

Started to hear loud rattle coming from rear of vehicle, thought maybe a heat shield around muffler went bad. Took it into the shop and they stated "not sure what happened, though you have something that has come loose in the resonator". Around $100 to get the resonator removed, have not quoted a new one from the dealer yet. I would imagine the replacement part will fail just as the original part has done.

14 Engine Exhaust System problem of the 2004 GMC Envoy

Failure Date: 02/20/2009

Investigated check engine light. Secondary air injection pump failure for emissions.

15 Engine Exhaust System problem of the 2002 GMC Envoy

Failure Date: 11/01/2008

Exhaust manifold leak.

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16 Engine Exhaust System problem of the 2002 GMC Envoy

Failure Date: 01/05/2004

Smell of burning plastic coming from underside of vehicle. Unknown if heat source is exhaust system or brakes.

17 Engine Exhaust System problem of the 2005 GMC Envoy

Failure Date: 07/20/2003

Smell of exhaust while driving. Noticed engine made a ticking sound which went away after engine got warm. Brought vehicle into a service center and a diagnosis of a cracked exhaust was made. Have noticed many other trailblazer and rnvoy owners complaints of exact same issue. Because of the nature of carbon monoxide poisoning in the cab I am entering this into the safety complaint database.

18 Engine Exhaust System problem of the 2000 GMC Envoy

Failure Date: 03/28/2001

When dealership changed oil, an oil pressure hose was found to be leaking oil from engine. Problem was repaired by the dealership. Vehicle has experienced several problems with the windshield wipers, deale has replaced the multifunction switch, rear wiper motor, front wiper terminal board and wiper module. Rear speakers have humming noises, speaker was shorting out, later consumer heard whistle noises in the rear speaker. When starting, there was a rattle noise, dealer found exhaust out of alignment. Creeking noise caused by faulty door pins and bushings, passenger side kick panel loose/falling off, dealer found right side panel loose. Alternator voltage drops with load below 35 amps, dealer replaced alternator, there was a squeak in the rear suspension, dealer found the e brake cable was chaffing on bushings, dealer repositioned e brake cable. Right front wheel bearing grinding, dealer replaced right front hub. Left front hub replaced due to growling, dealer found hub was worn.

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Other Common Engine And Engine Cooling related problems of GMC Envoy


Fuel Economy of Envoy Vehicles
Envoy Service Bulletins
Envoy Safety Recalls
Envoy Defect Investigations