Recalls 1, 2, and 3 all describe the same underlying defect: the rocker cover gasket on the 3.8L engine degrades and allows oil to seep out, where it can drip onto the hot exhaust manifold and start a fire. I'll treat these as a single issue.
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The 2004 Buick Regal has 3 recalls, all tied to the same fire risk: the rocker cover gasket on the 3.8L engine can degrade and allow oil to seep out and drip onto the hot exhaust manifold.
Hard braking in particular can cause pooled oil to shift toward the exhaust manifold, raising the chance of ignition. All three recalls trace back to this same gasket and oil leak issue, with prior repair attempts not fully resolving the problem across the affected production range.
At a glance
What can fail
Engine oil may leak onto the hot exhaust manifold through the front valve cover gasket, creating a fire risk. Previous repair attempts did not fully eliminate this problem.
What the fix does
Dealers will replace the front valve cover and gasket to stop the oil leak and eliminate the fire risk.
Summarized — see the official notice for exact wording, dates, and contacts.
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At a glance
What can fail
The valve cover gasket may leak, allowing oil to seep from the engine.
What the fix does
Dealers will replace the front valve cover and gasket after removing the plastic cover and oil fill tube extension.
Summarized — see the official notice for exact wording, dates, and contacts.
At a glance
What can fail
The front rocker cover gasket can wear and leak oil onto the hot exhaust manifold. During hard braking, oil drops may ignite on the manifold and spread to plastic spark plug wire channels, risking an engine fire.
What the fix does
Dealers will remove the spark plug wire retention channel and install new retainers. For supercharged engines, dealers will also replace the front rocker cover gasket.
Summarized — see the official notice for exact wording, dates, and contacts.
