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2004 Buick Regal Problems: 1 Known Issue

2004 model year · NHTSA recalls, manufacturer TSBs, and owner forum reports · Updated September 2026

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Issue summary

According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2004 Buick Regal has 1 documented issue, with 1 rated critical. The most serious is Valve Cover Gasket Oil Leak Onto Exhaust Manifold — Fire Risk (NHTSA 15V201000). DIY maintenance guides at au7o.io.

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All 1 Known Issue

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On the 2004 Buick Regal, 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.

Common Symptoms

  • Engine oil leaking from the valve cover area
  • Smell of burning oil while driving or after shutdown
  • Smoke from the engine bay where oil contacts the hot exhaust manifold

How to Fix

The repair is free at any Buick dealer. The dealer removes the plastic engine cover and the plastic oil fill tube extension, then replaces the front valve cover and its gasket. Owner notification began April 24, 2015, so a car bought used may already have been fixed — or may have been missed if a previous owner never responded. Enter your VIN at nhtsa.gov/recalls to see whether campaign 15V201000 is still open on your Regal, and call Buick customer service at 1-800-521-7300 with questions. Reference GM recall number 14574.

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Frequently Asked Questions

What are the most common Buick Regal problems?

According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2004 Buick Regal has 1 documented issue. The documented issue is: Valve Cover Gasket Oil Leak Onto Exhaust Manifold — Fire Risk (NHTSA 15V201000). Of these, 1 is rated critical and should be addressed promptly.

Is the Buick Regal reliable?

The 2004 Buick Regal has 1 known issue compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 1 issue is rated critical: Valve Cover Gasket Oil Leak Onto Exhaust Manifold — Fire Risk (NHTSA 15V201000). Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.

What is the 2004 Buick Regal Valve Cover Gasket Oil Leak Onto Exhaust Manifold — Fire Risk (NHTSA 15V201000)?

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… Severity: high.

Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.

Data compiled from NHTSA recalls, manufacturer TSBs, automotive forums, and AI-assisted research. No aggregated owner-report counts available for this vehicle yet.