1997-2004, 2011-2020 Buick Regal Problems & Issues

GM notified NHTSA on April 2, 2015 that certain 2004 Buick Regal sedans built in a narrow window — April 9, 2003 through June 1, 2003 — can develop a leaking valve cover gasket. Because of where the leak sits, escaping engine oil can drip down onto the hot surface of the exhaust manifold, which GM says increases the risk of an under-hood fire. Only Regals assembled in that spring-2003 date range are named, so two 2004 Regals sitting side by side may not both be covered — build date, not model year alone, decides it. The campaign as a whole (GM number 14574) covers 330,742 vehicles across the several GM models included in it; that figure is campaign-wide and says nothing about how many Regals are involved. GM expanded the campaign on May 18, 2015 to add other vehicles.

Buick Regals from 1997 through 2003 equipped with the 3.8L naturally aspirated V6 fall under GM recall 09V116000. The defect is an oil leak path that lets drops of engine oil land on the exhaust manifold when the car is braked hard. Should the manifold be hot enough and the oil run underneath the heat shield, the oil can ignite into a small flame. From there the fire can travel to the plastic spark plug wire channel and beyond, which is what makes an otherwise ordinary oil weep a fire hazard rather than just a mess. This is one of the longest year spans in the campaign — nearly every 3.8L naturally aspirated Regal of that generation is in scope. Supercharged Regal GS models are not covered by this campaign, which is specific to the naturally aspirated 3.8L. NHTSA lists 1,497,516 vehicles for the campaign as a whole, spanning all the GM models involved.

GM recalled Buick Regals built for the 1997-2003 model years that came with the supercharged 3.8L V-6 — in the Regal line that is the GS-style supercharged car, not the naturally aspirated version. On these engines the front rocker (valve) cover gasket runs at higher temperatures than normal, so the gasket can degrade earlier than expected and begin letting engine oil seep out. NHTSA's consequence statement is the serious part: oil that seeps or is spilled at the front of the engine can be flung onto the exhaust manifold, and hard braking is specifically called out as the motion that deposits those drops. If the manifold is hot enough and the oil runs down below the heat shield, it can ignite into a small flame and, in some cases, a larger underhood fire. The campaign covers 207,542 vehicles in total across every model included in the recall — that figure is campaign-wide and is not a count of Regals. Until the remedy was performed, GM advised owners not to park the car in a garage, carport or other structure, to have the dealer inspect it free if they noticed a burning odor, and to use premium (91 octane or higher) fuel.

GM bulletin 13-06-01-003I addresses excessive oil consumption in certain 2011–2013 Regal vehicles with the 2.4L LAF/LEA engine. It requires measurement and preliminary checks rather than diagnosing worn rings from smoke, misfire or compression alone.

The 2.0L Turbo LHU (2011-2013) and LTG (2014+) in Regal — and shared LaCrosse, Cadillac ATS/CTS — develops timing chain stretch around 80,000-130,000 miles. Symptoms: cold-start rattle, P0008/P0017 codes, eventual loss of cam timing. Aggravated by extended oil intervals and stop-start fleet use.

Like other GM direct-injected engines, the Regal's 2.0T and 2.4L DI engines accumulate carbon deposits on the back of the intake valves because fuel no longer washes the valves clean. Over tens of thousands of miles this causes cold-start misfires, rough idle, hesitation, and reduced power and economy. It is a well-documented owner complaint on the turbo cars in particular.

The Aisin AF40 6-speed automatic in 2011-2013 Regal 2.0L Turbo (and 2010-2017 LaCrosse 4-cyl, 2008-2017 Opel Insignia A) develops harsh 1-2 and 2-3 shifts, torque-converter shudder at light throttle, and delayed engagement, usually at 80,000-150,000 miles. GM's "lifetime fill" claim is widely disputed by independent shops.

Regals equipped with the GM 6T40/6T70 six-speed automatic can develop torque-converter shudder, slipping or flare on the 2-6 shift, and harsh/delayed shifts. The 6T40 issue is commonly debris blocking the 2-6 clutch regulator valve circuit; the 6T70 suffers wear in the accumulator/solenoid valve bores and torque-converter clutch shudder, sometimes worsened by overheated, degraded fluid.

2018-2020 fifth-generation Regals (Sportback/TourX) were recalled because a software error in the electronic brake control module (EBCM) may fail to activate the hydraulic-brake boost backup if vacuum brake assist is lost. The result is a hard, high-effort brake pedal with substantially reduced braking performance and increased stopping distance. GM recalled roughly 23,734 vehicles (NHTSA 22V465, June 2022).

Buick Regal models from 2012 and 2013 built with the eAssist mild-hybrid system are covered by GM recall 13V173000 (GM campaign 13136), an NHTSA electrical-system recall covering 42,904 vehicles campaign-wide across all of the models included in it. On an affected Regal, the Generator Control Module (GCM) that manages the eAssist system may not function properly. According to NHTSA, this can lead to a gradual loss of battery charge along with illumination of the malfunction indicator light. If the Regal keeps being driven in that condition, the engine may stall and/or the car may fail to start afterward. NHTSA also warns that the failing module can produce a burning or melting odor, smoke, and possibly a fire in the trunk — which is where the eAssist hardware lives on this car. Note that this applies only to eAssist-equipped Regals; non-eAssist Regals are outside the recall population.

GM recalled certain 2016 Regals (built Aug 2015 – Feb 2016) because a defective circuit board in the electric belt-drive rack-and-pinion steering gear could cause a sudden loss of power steering assist, sharply increasing steering effort and crash risk. Owners have also reported steering jolting or locking at speed.

Certain 2012-2013 Regals (including Turbo and GS) sold or registered in road-salt states have rear suspension toe links that received improper e-coat corrosion protection. In road-salt states, the toe link can corrode and eventually fracture, causing a sudden loss of rear-wheel control. This has been the subject of repeated GM recalls (20V764 in 2020, 21V633 in 2021, and 26V113 in 2026 covering ~17,050 additional 2012-2013 Turbo/GS vehicles), making it one of the most safety-significant Regal defects.