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Pontiac GTO Complete Workshop Service Repair Manual 2004 2005 2006

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🏷️ Basic Information Identification Make: Pontiac Model: GTO Years Covered: 2004, 2005, 2006 👋 Introduction Market Position Market Segment: Performance Coupe, Muscle Car Revival Competitive Analysis Key Competitors: Ford Mustang, Chevrolet Camaro, Dodge Challenger (contemporary competitors), earlier muscle cars like Camaro, Firebird, Challenger. Key Features Of Gto Performance Focus: Emphasized V8 engine power, rear-wheel drive platform, and performance-oriented handling. Australian Heritage: Based on the Holden Monaro platform, offering a unique international flavor. Manual Value Proposition Cost Saving: Enables DIY repairs, saving significant labor costs. Ease Of Use: Step-by-step instructions and illustrations make complex tasks manageable. 📋 Manual Details Coverage Areas All Models Engines Trims Transmissions: True Page Count Estimated Page Count: Approximately 1500-2500 (typical for a complete workshop manual of this era, actual may vary) Manual Type Manual Type: Workshop Service Repair Manual Language Language: English Format Format: Downloadable Digital File (PDF) 📖 Manual Coverage Systems Covered Engine Mechanical: Engine assembly, disassembly, internal components, cylinder head, block, crankshaft, pistons, connecting rods, lubrication system, cooling system, timing system. Engine Performance: Fuel injection system, ignition system, emission controls, turbocharging/supercharging (if applicable), engine diagnostics. Transmission Manual: Manual transmission removal, disassembly, assembly, clutch system, gear shifting mechanisms. Transmission Automatic: Automatic transmission removal, disassembly, assembly, torque converter, hydraulic controls, electronic controls. Drivetrain: Front-wheel drive/rear-wheel drive system, driveshafts, constant velocity joints, differentials, axles, wheel bearings. Suspension: Front and rear suspension components, shock absorbers, struts, springs, control arms, bushings, alignment specifications. Steering: Steering column, steering rack, power steering system, pump, hoses, steering linkage, alignment. Brakes: Brake system components (discs, pads, calipers, drums, shoes), master cylinder, brake lines, ABS system, parking brake. Electrical System: Battery, charging system, starter motor, lighting system, instrumentation, power windows, power locks, mirrors, wipers. HVAC: Heating, ventilation, and air conditioning system, refrigerant handling, components, diagnostics. Body And Frame: Body panels, doors, hood, trunk, bumpers, interior trim, chassis structure, rust repair, collision repair basics. Restraints: Airbag system, seat belts, SRS components, diagnostics. Diagnostics: On-Board Diagnostics (OBD-II) system, diagnostic trouble codes (DTCs), scan tool usage, troubleshooting procedures. Procedures Included Maintenance: Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt replacement, tune-ups. Troubleshooting: Step-by-step diagnostic guides for common and uncommon issues, symptom-based troubleshooting. Repair: Detailed instructions for component removal, replacement, and adjustment for all covered systems. Overhaul: Complete engine and transmission overhaul procedures, including specifications and tolerances. Diagnostics And Testing: Procedures for testing individual components and systems using appropriate tools and equipment. Wiring Diagrams: Comprehensive electrical wiring diagrams for all vehicle systems. Specifications And Tolerances: All necessary torque specifications, clearances, and alignment settings. Technical Depth Depth Of Coverage: Comprehensive, from basic maintenance to complete engine and transmission rebuilds, including diagnostics and electrical troubleshooting. 📊 Manual Specifications File Format File Format: PDF Print Quality Print Quality: High-quality, printable pages with clear text and images. Binding Type Binding Type: Not Applicable (Digital Download) Paper Type Paper Type: Not Applicable (Digital Download) Software Requirements Required Software: Adobe Reader (or compatible PDF viewer) Accessibility Device Compatibility: PC, Mac, Tablets, Smartphones ⚙️ Engine Specifications Primary Engine 2004 2005 Engine Code: LS1 Engine Type: 5.7L V8 OHV (Gen III Small Block) Horsepower: 350 hp @ 5200 rpm Torque: 365 lb-ft @ 4000 rpm Primary Engine 2006 Engine Code: LS2 Engine Type: 6.0L V8 OHV (Gen IV Small Block) Horsepower: 400 hp @ 5200 rpm Torque: 400 lb-ft @ 4400 rpm Fuel System Fuel Delivery: Multi-Port Fuel Injection (MPFI) Fuel Type: Unleaded gasoline (Premium recommended) Cooling System Coolant Type: Dex-Cool (Orange) Extended Life Antifreeze/Coolant Lubrication System Oil Type: SAE 5W-30 Synthetic Engine Oil (API SM or higher) Oil Capacity: 5.5 US Quarts (with filter) 🔧 Transmission Standard Transmission Standard Transmission Type: T-56 6-speed Manual Transmission Optional Transmission Optional Transmission Type: 4L65-E 4-speed Automatic Transmission Transmission Fluid Manual Manual Transmission Fluid: Dexron III/Mercon Automatic Transmission Fluid (for T-56 synchronizers and bearings) Transmission Fluid Automatic Automatic Transmission Fluid: Dexron VI Automatic Transmission Fluid 📐 Dimensions Exterior Dimensions Wheelbase: 110.2 inches (2799 mm) Length: 190.3 inches (4833 mm) Width: 72.9 inches (1852 mm) Height: 54.5 inches (1384 mm) Weights Curb Weight: Approx. 3700-3850 lbs (1680-1746 kg) Gross Vehicle Weight Rating: Approx. 4700 lbs (2132 kg) 🛡️ Safety Features Ratings NHTSA Front Impact Rating: 5-Star (Driver and Passenger - 2004 model year) NHTSA Side Impact Rating: 5-Star (Front Passenger - 2004 model year) Active Features ABS: Standard Anti-lock Braking System (ABS) Traction Control: Standard Traction Control System (TCS) Passive Features Airbags: Dual Frontal Airbags, Available Side-Impact Airbags (optional on early models, standard later) Seatbelts: 3-point front seat belts with pretensioners, rear seat belts. 💡 Technology Features Infotainment Audio System: Standard AM/FM/CD player, optional premium audio systems (e.g., Pioneer). Climate Control: Manual or optional automatic climate control. Driver Assistance Cruise Control: Standard cruise control. Connectivity Dashboard Features: Digital odometer, analog gauges for tachometer, speedometer, fuel, and temperature. 🔧 Maintenance Service Intervals Oil Oil Change Interval: Every...
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Stichworte: 2004 2005 2006 Car Cars GTO Pontiac
Pontiac GTO Complete Workshop Service Repair Manual 2004 2005 2006Pontiac GTO Complete Workshop Service Repair Manual 2004 2005 2006Pontiac GTO Complete Workshop Service Repair Manual 2004 2005 2006
🏷️ Basic Information
Identification
Make:
Pontiac
Model:
GTO
Years Covered:
2004, 2005, 2006
👋 Introduction
Market Position
Market Segment:
Performance Coupe, Muscle Car Revival
Competitive Analysis
Key Competitors:
Ford Mustang, Chevrolet Camaro, Dodge Challenger (contemporary competitors), earlier muscle cars like Camaro, Firebird, Challenger.
Key Features Of Gto
Performance Focus:
Emphasized V8 engine power, rear-wheel drive platform, and performance-oriented handling.
Australian Heritage:
Based on the Holden Monaro platform, offering a unique international flavor.
Manual Value Proposition
Cost Saving:
Enables DIY repairs, saving significant labor costs.
Ease Of Use:
Step-by-step instructions and illustrations make complex tasks manageable.
📋 Manual Details
Coverage Areas
All Models Engines Trims Transmissions:
True
Page Count
Estimated Page Count:
Approximately 1500-2500 (typical for a complete workshop manual of this era, actual may vary)
Manual Type
Manual Type:
Workshop Service Repair Manual
Language
Language:
English
Format
Format:
Downloadable Digital File (PDF)
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Engine assembly, disassembly, internal components, cylinder head, block, crankshaft, pistons, connecting rods, lubrication system, cooling system, timing system.
Engine Performance:
Fuel injection system, ignition system, emission controls, turbocharging/supercharging (if applicable), engine diagnostics.
Transmission Manual:
Manual transmission removal, disassembly, assembly, clutch system, gear shifting mechanisms.
Transmission Automatic:
Automatic transmission removal, disassembly, assembly, torque converter, hydraulic controls, electronic controls.
Drivetrain:
Front-wheel drive/rear-wheel drive system, driveshafts, constant velocity joints, differentials, axles, wheel bearings.
Suspension:
Front and rear suspension components, shock absorbers, struts, springs, control arms, bushings, alignment specifications.
Steering:
Steering column, steering rack, power steering system, pump, hoses, steering linkage, alignment.
Brakes:
Brake system components (discs, pads, calipers, drums, shoes), master cylinder, brake lines, ABS system, parking brake.
Electrical System:
Battery, charging system, starter motor, lighting system, instrumentation, power windows, power locks, mirrors, wipers.
HVAC:
Heating, ventilation, and air conditioning system, refrigerant handling, components, diagnostics.
Body And Frame:
Body panels, doors, hood, trunk, bumpers, interior trim, chassis structure, rust repair, collision repair basics.
Restraints:
Airbag system, seat belts, SRS components, diagnostics.
Diagnostics:
On-Board Diagnostics (OBD-II) system, diagnostic trouble codes (DTCs), scan tool usage, troubleshooting procedures.
Procedures Included
Maintenance:
Oil changes, filter replacements, fluid checks and top-offs, spark plug replacement, belt replacement, tune-ups.
Troubleshooting:
Step-by-step diagnostic guides for common and uncommon issues, symptom-based troubleshooting.
Repair:
Detailed instructions for component removal, replacement, and adjustment for all covered systems.
Overhaul:
Complete engine and transmission overhaul procedures, including specifications and tolerances.
Diagnostics And Testing:
Procedures for testing individual components and systems using appropriate tools and equipment.
Wiring Diagrams:
Comprehensive electrical wiring diagrams for all vehicle systems.
Specifications And Tolerances:
All necessary torque specifications, clearances, and alignment settings.
Technical Depth
Depth Of Coverage:
Comprehensive, from basic maintenance to complete engine and transmission rebuilds, including diagnostics and electrical troubleshooting.
📊 Manual Specifications
File Format
File Format:
PDF
Print Quality
Print Quality:
High-quality, printable pages with clear text and images.
Binding Type
Binding Type:
Not Applicable (Digital Download)
Paper Type
Paper Type:
Not Applicable (Digital Download)
Software Requirements
Required Software:
Adobe Reader (or compatible PDF viewer)
Accessibility
Device Compatibility:
PC, Mac, Tablets, Smartphones
⚙️ Engine Specifications
Primary Engine 2004 2005
Engine Code:
LS1
Engine Type:
5.7L V8 OHV (Gen III Small Block)
Horsepower:
350 hp @ 5200 rpm
Torque:
365 lb-ft @ 4000 rpm
Primary Engine 2006
Engine Code:
LS2
Engine Type:
6.0L V8 OHV (Gen IV Small Block)
Horsepower:
400 hp @ 5200 rpm
Torque:
400 lb-ft @ 4400 rpm
Fuel System
Fuel Delivery:
Multi-Port Fuel Injection (MPFI)
Fuel Type:
Unleaded gasoline (Premium recommended)
Cooling System
Coolant Type:
Dex-Cool (Orange) Extended Life Antifreeze/Coolant
Lubrication System
Oil Type:
SAE 5W-30 Synthetic Engine Oil (API SM or higher)
Oil Capacity:
5.5 US Quarts (with filter)
🔧 Transmission
Standard Transmission
Standard Transmission Type:
T-56 6-speed Manual Transmission
Optional Transmission
Optional Transmission Type:
4L65-E 4-speed Automatic Transmission
Transmission Fluid Manual
Manual Transmission Fluid:
Dexron III/Mercon Automatic Transmission Fluid (for T-56 synchronizers and bearings)
Transmission Fluid Automatic
Automatic Transmission Fluid:
Dexron VI Automatic Transmission Fluid
📐 Dimensions
Exterior Dimensions
Wheelbase:
110.2 inches (2799 mm)
Length:
190.3 inches (4833 mm)
Width:
72.9 inches (1852 mm)
Height:
54.5 inches (1384 mm)
Weights
Curb Weight:
Approx. 3700-3850 lbs (1680-1746 kg)
Gross Vehicle Weight Rating:
Approx. 4700 lbs (2132 kg)
🛡️ Safety Features
Ratings
NHTSA Front Impact Rating:
5-Star (Driver and Passenger - 2004 model year)
NHTSA Side Impact Rating:
5-Star (Front Passenger - 2004 model year)
Active Features
ABS:
Standard Anti-lock Braking System (ABS)
Traction Control:
Standard Traction Control System (TCS)
Passive Features
Airbags:
Dual Frontal Airbags, Available Side-Impact Airbags (optional on early models, standard later)
Seatbelts:
3-point front seat belts with pretensioners, rear seat belts.
💡 Technology Features
Infotainment
Audio System:
Standard AM/FM/CD player, optional premium audio systems (e.g., Pioneer).
Climate Control:
Manual or optional automatic climate control.
Driver Assistance
Cruise Control:
Standard cruise control.
Connectivity
Dashboard Features:
Digital odometer, analog gauges for tachometer, speedometer, fuel, and temperature.
🔧 Maintenance
Service Intervals Oil
Oil Change Interval:
Every 7,500 miles or 12 months, whichever comes first (with synthetic oil).
Service Intervals Filters
Oil Filter Replacement:
Replace with every oil change.
Engine Air Filter Replacement:
Every 30,000 miles or as needed based on inspection.
Cabin Air Filter Replacement:
Every 15,000 miles or annually.
Service Intervals Spark Plugs
Spark Plug Replacement Ls1:
Platinum plugs: 100,000 miles. Iridium plugs: 100,000+ miles.
Spark Plug Replacement Ls2:
Platinum/Iridium plugs: 100,000+ miles.
Service Intervals Coolant
Coolant Flush Interval:
Every 5 years or 150,000 miles (for Dex-Cool).
Fluid Specifications
Brake Fluid Type:
DOT 3 or DOT 4 (check specific vehicle placard/manual)
Power Steering Fluid Type:
Dexron III/Mercon Automatic Transmission Fluid
Known Issues
Common Issues Suspension:
Worn front control arm bushings, ball joints, and sway bar links leading to clunking noises and poor handling.
Common Issues Electrical:
Issues with window regulators, power lock actuators, and some interior lighting components.
Common Issues Engine:
Oil leaks from valve covers or oil pan, potential for intake manifold gasket leaks (less common on LS1/LS2).
Common Issues Exhaust:
Exhaust manifold gaskets can fail, leading to exhaust leaks and ticking noises.
📚 Vehicle History
Brand Heritage
Pontiac Legacy:
Pontiac's long history of performance-oriented vehicles, often associated with muscle car culture.
Model Evolution
Gto Revival:
Reintroduction of the GTO nameplate for the North American market, leveraging Holden's rear-wheel-drive platform.
Year Over Year Changes:
2004: Initial launch with 5.7L LS1. 2005: Minor styling tweaks, improved suspension. 2006: Introduction of 6.0L LS2 engine, revised styling, improved braking, and enhanced interior features.
Production
Production Location:
Elizabeth, South Australia, Australia (by Holden)
Production Years Na:
2004-2006
🏆 Awards & Recognition
Recognitions
Award Listing:
While the GTO was met with mixed reviews, its performance-oriented nature was often acknowledged. Specific awards are less prominent than its position as a revival of a classic nameplate.
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