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Pontiac GTO 2004-2006 Factory Service Workshop Repair Manual

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🏷️ Basic Information Identification Make: Pontiac Model: GTO Year: 2004-2006 Generation Generation Code: V (2004-2006) Codes Platform: GM Zeta platform 👋 Introduction Market Position Market Position: A modern performance coupe designed to evoke the spirit of the original Australian-market Holden Monaro and the classic American GTO muscle car heritage. Competitive Analysis Competitive Vehicles: Ford Mustang, Chevrolet Camaro, Dodge Challenger (though often considered more of a direct competitor to European performance coupes of its era due to its chassis and engine origins). Key Features Key Features: Rear-wheel drive, V8 engine options, performance-oriented chassis, distinctive styling, aggressive exhaust note. Target Audience Target Audience: Enthusiasts seeking a potent, rear-wheel-drive V8 coupe with a blend of American muscle car appeal and modern performance capabilities. Also appealing to DIY mechanics and performance tuners. 📋 Manual Details Coverage Areas Coverage Summary: Comprehensive service, repair, and maintenance for all systems. Specific Systems Covered: Engine Mechanical, Engine Electrical, Emission Control, Fuel System, Clutch, Manual Transaxle, Automatic Transaxle, Driveshaft & Axle, Suspension, Steering, Restraint System, Brake System, Body (Interior & Exterior), Body Electrical System, HVAC. Page Count Estimated Page Count: Varies by specific model year and engine option, but comprehensive factory service manuals typically range from 1500 to 3000+ pages. Manual Type Manual Type: Factory Service Manual / Workshop Manual / Repair Manual Language Language: English Format Format: PDF with Index 📖 Manual Coverage Systems Covered Engine Mechanical: Detailed procedures for engine assembly, disassembly, internal component repair, timing, and diagnostics. Engine Electrical: Wiring diagrams, component testing, diagnostic trouble codes (DTCs), ECM/PCM strategies, ignition system, charging system. Emission Control: Evaporative Emission Control (EVAP) system, catalytic converter operation, EGR system, emissions testing procedures. Fuel System: Fuel pump operation, fuel injectors, fuel pressure testing, fuel tank and lines, throttle body. Clutch System: Clutch hydraulic system, clutch disc and pressure plate replacement, pilot bearing, release bearing. Manual Transaxle: Internal component repair, gear inspection, shift linkage adjustment, fluid capacity and type, clutch engagement. Automatic Transaxle: Transmission fluid (ATF) type and capacity, valve body diagnosis, torque converter, shift solenoids, transmission control module (TCM) diagnostics. Driveshaft And Axle: CV joint inspection and replacement, driveshaft balance, differential service, propeller shaft. Suspension System: Front and rear suspension component identification, alignment specifications, shock absorber and strut replacement, ball joints, control arms. Steering System: Power steering pump, steering gear/rack and pinion, tie rod ends, steering column, alignment. Restraint System: Airbag system operation, SRS component replacement (SRS module, sensors, airbags), seatbelt inspection and replacement. Brake System: Brake pad and rotor replacement, brake fluid type and bleeding procedures, ABS system diagnostics, parking brake adjustment. Body Interior Exterior: Panel removal and installation, door mechanisms, interior trim, weatherstripping, glass replacement, bumper fascia repair. Body Electrical: Lighting systems (headlights, taillights, interior), power windows, power locks, central locking, mirror controls, wiper system. HVAC System: A/C system refrigerant charge, compressor replacement, HVAC blower motor, climate control module, heater core, cabin air filter. Procedures Included Maintenance Procedures: Oil changes, filter replacements, fluid checks and changes, tire rotation, spark plug replacement, belt inspection and replacement. Repair Procedures: Engine rebuilds, transmission overhauls, brake caliper replacement, suspension component renewal, electrical system troubleshooting and repair. Diagnostic Procedures: Systematic troubleshooting guides, use of diagnostic scan tools, interpretation of fault codes, wiring diagram analysis. Installation Procedures: Component replacement guidelines, torque specifications for critical fasteners, alignment procedures. Technical Depth Depth Of Coverage: From basic DIY maintenance to advanced engine and transmission rebuilds, comprehensive diagnostics, and electrical system troubleshooting. 📊 Manual Specifications File Format File Format: PDF Searchable Text: Yes (typical for factory service manuals). Index Included: Yes Print Quality Print Quality Description: High-resolution scans of original factory documentation, ensuring clear diagrams and text. Binding Type Binding Type: N/A (Digital PDF) Paper Type Paper Type: N/A (Digital PDF) ⚙️ Engine Specifications Primary Engine 2004 Engine Code: LS1 Engine Type: 5.7L V8 (346 cu in) Naturally Aspirated LS1 V8 Horsepower 2004: 350 hp @ 5200 rpm Torque 2004: 365 lb-ft @ 4000 rpm Primary Engine 2005 2006 Engine Code: LS2 Engine Type: 6.0L V8 (364 cu in) Naturally Aspirated LS2 V8 Horsepower 2005 2006: 400 hp @ 5200 rpm Torque 2005 2006: 400 lb-ft @ 4400 rpm Performance Compression Ratio: LS1: 10.1:1; LS2: 10.9:1 Redline: Approx. 6000 rpm Fuel System Fuel Delivery: Sequential Electronic Fuel Injection (SEFI) Recommended Fuel: Premium Unleaded (91 octane or higher recommended) Engine Management Engine Control Module: GM PCM (Powertrain Control Module) 🔧 Transmission Standard 2004 Transmission Type: Tremec T-56 6-speed Manual Optional 2004 Transmission Type: 4-speed Automatic (4L60-E) Standard 2005 2006 Transmission Type: Tremec T-56 6-speed Manual Optional 2005 2006 Transmission Type: 4-speed Automatic (4L65-E) Features Clutch Type: Hydraulic Release Bearing (internal to transmission on T-56) Fluid Specifications Manual Transmission Fluid: Dexron III or equivalent (e.g., Castrol Syntrans Multivehicle 75W-90, Mobil 1 Synthetic Gear Lube 75W-90) Automatic Transmission Fluid: Dexron VI (recommended for 4L65-E) or Dexron III (for 4L60-E) 📐 Dimensions Exterior...
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Pontiac GTO 2004-2006 Factory Service Workshop Repair Manual
🏷️ Basic Information
Identification
Make:
Pontiac
Model:
GTO
Year:
2004-2006
Generation
Generation Code:
V (2004-2006)
Codes
Platform:
GM Zeta platform
👋 Introduction
Market Position
Market Position:
A modern performance coupe designed to evoke the spirit of the original Australian-market Holden Monaro and the classic American GTO muscle car heritage.
Competitive Analysis
Competitive Vehicles:
Ford Mustang, Chevrolet Camaro, Dodge Challenger (though often considered more of a direct competitor to European performance coupes of its era due to its chassis and engine origins).
Key Features
Key Features:
Rear-wheel drive, V8 engine options, performance-oriented chassis, distinctive styling, aggressive exhaust note.
Target Audience
Target Audience:
Enthusiasts seeking a potent, rear-wheel-drive V8 coupe with a blend of American muscle car appeal and modern performance capabilities. Also appealing to DIY mechanics and performance tuners.
📋 Manual Details
Coverage Areas
Coverage Summary:
Comprehensive service, repair, and maintenance for all systems.
Specific Systems Covered:
Engine Mechanical, Engine Electrical, Emission Control, Fuel System, Clutch, Manual Transaxle, Automatic Transaxle, Driveshaft & Axle, Suspension, Steering, Restraint System, Brake System, Body (Interior & Exterior), Body Electrical System, HVAC.
Page Count
Estimated Page Count:
Varies by specific model year and engine option, but comprehensive factory service manuals typically range from 1500 to 3000+ pages.
Manual Type
Manual Type:
Factory Service Manual / Workshop Manual / Repair Manual
Language
Language:
English
Format
Format:
PDF with Index
📖 Manual Coverage
Systems Covered
Engine Mechanical:
Detailed procedures for engine assembly, disassembly, internal component repair, timing, and diagnostics.
Engine Electrical:
Wiring diagrams, component testing, diagnostic trouble codes (DTCs), ECM/PCM strategies, ignition system, charging system.
Emission Control:
Evaporative Emission Control (EVAP) system, catalytic converter operation, EGR system, emissions testing procedures.
Fuel System:
Fuel pump operation, fuel injectors, fuel pressure testing, fuel tank and lines, throttle body.
Clutch System:
Clutch hydraulic system, clutch disc and pressure plate replacement, pilot bearing, release bearing.
Manual Transaxle:
Internal component repair, gear inspection, shift linkage adjustment, fluid capacity and type, clutch engagement.
Automatic Transaxle:
Transmission fluid (ATF) type and capacity, valve body diagnosis, torque converter, shift solenoids, transmission control module (TCM) diagnostics.
Driveshaft And Axle:
CV joint inspection and replacement, driveshaft balance, differential service, propeller shaft.
Suspension System:
Front and rear suspension component identification, alignment specifications, shock absorber and strut replacement, ball joints, control arms.
Steering System:
Power steering pump, steering gear/rack and pinion, tie rod ends, steering column, alignment.
Restraint System:
Airbag system operation, SRS component replacement (SRS module, sensors, airbags), seatbelt inspection and replacement.
Brake System:
Brake pad and rotor replacement, brake fluid type and bleeding procedures, ABS system diagnostics, parking brake adjustment.
Body Interior Exterior:
Panel removal and installation, door mechanisms, interior trim, weatherstripping, glass replacement, bumper fascia repair.
Body Electrical:
Lighting systems (headlights, taillights, interior), power windows, power locks, central locking, mirror controls, wiper system.
HVAC System:
A/C system refrigerant charge, compressor replacement, HVAC blower motor, climate control module, heater core, cabin air filter.
Procedures Included
Maintenance Procedures:
Oil changes, filter replacements, fluid checks and changes, tire rotation, spark plug replacement, belt inspection and replacement.
Repair Procedures:
Engine rebuilds, transmission overhauls, brake caliper replacement, suspension component renewal, electrical system troubleshooting and repair.
Diagnostic Procedures:
Systematic troubleshooting guides, use of diagnostic scan tools, interpretation of fault codes, wiring diagram analysis.
Installation Procedures:
Component replacement guidelines, torque specifications for critical fasteners, alignment procedures.
Technical Depth
Depth Of Coverage:
From basic DIY maintenance to advanced engine and transmission rebuilds, comprehensive diagnostics, and electrical system troubleshooting.
📊 Manual Specifications
File Format
File Format:
PDF
Searchable Text:
Yes (typical for factory service manuals).
Index Included:
Yes
Print Quality
Print Quality Description:
High-resolution scans of original factory documentation, ensuring clear diagrams and text.
Binding Type
Binding Type:
N/A (Digital PDF)
Paper Type
Paper Type:
N/A (Digital PDF)
⚙️ Engine Specifications
Primary Engine 2004
Engine Code:
LS1
Engine Type:
5.7L V8 (346 cu in) Naturally Aspirated LS1 V8
Horsepower 2004:
350 hp @ 5200 rpm
Torque 2004:
365 lb-ft @ 4000 rpm
Primary Engine 2005 2006
Engine Code:
LS2
Engine Type:
6.0L V8 (364 cu in) Naturally Aspirated LS2 V8
Horsepower 2005 2006:
400 hp @ 5200 rpm
Torque 2005 2006:
400 lb-ft @ 4400 rpm
Performance
Compression Ratio:
LS1: 10.1:1; LS2: 10.9:1
Redline:
Approx. 6000 rpm
Fuel System
Fuel Delivery:
Sequential Electronic Fuel Injection (SEFI)
Recommended Fuel:
Premium Unleaded (91 octane or higher recommended)
Engine Management
Engine Control Module:
GM PCM (Powertrain Control Module)
🔧 Transmission
Standard 2004
Transmission Type:
Tremec T-56 6-speed Manual
Optional 2004
Transmission Type:
4-speed Automatic (4L60-E)
Standard 2005 2006
Transmission Type:
Tremec T-56 6-speed Manual
Optional 2005 2006
Transmission Type:
4-speed Automatic (4L65-E)
Features
Clutch Type:
Hydraulic Release Bearing (internal to transmission on T-56)
Fluid Specifications
Manual Transmission Fluid:
Dexron III or equivalent (e.g., Castrol Syntrans Multivehicle 75W-90, Mobil 1 Synthetic Gear Lube 75W-90)
Automatic Transmission Fluid:
Dexron VI (recommended for 4L65-E) or Dexron III (for 4L60-E)
📐 Dimensions
Exterior
Length:
191.4 inches (4862 mm)
Width:
72.4 inches (1839 mm)
Height:
54.2 inches (1377 mm)
Wheelbase:
110.2 inches (2800 mm)
Weights
Curb Weight Manual:
Approx. 3740 lbs (1700 kg)
Curb Weight Automatic:
Approx. 3830 lbs (1740 kg)
Cargo
Trunk Volume:
Approx. 13.1 cu ft (371 L)
🛡️ Safety Features
Ratings
NHTSA Front Impact Driver:
5-Star
NHTSA Front Impact Passenger:
5-Star
IIHS Front Offset Impact:
Good
Active Features
ABS:
Standard 4-wheel disc anti-lock braking system (ABS)
Traction Control:
Standard
Passive Features
Airbags:
Standard front driver and passenger airbags, optional side-impact airbags.
💡 Technology Features
Infotainment
Infotainment System:
Standard AM/FM stereo with CD player. Optional premium sound system. Basic digital displays for climate control and information.
Connectivity:
Limited by era; no standard Bluetooth or USB ports. Aftermarket upgrades are common.
Driver Assistance
Driver Assistance Features:
Primarily focused on safety with ABS and traction control. No advanced driver-assistance systems (ADAS) like adaptive cruise control or lane keeping assist.
🔧 Maintenance
Service Intervals Oil
Oil Change Interval:
Every 7,500 miles (12,000 km) or 6 months, whichever comes first, under normal driving conditions. Consult the manual for severe driving conditions.
Service Intervals Filters
Air Filter Replacement:
Inspect every 15,000 miles (24,000 km), replace as needed. The manual will specify replacement intervals based on driving conditions.
Cabin Air Filter Replacement:
Inspect every 15,000 miles (24,000 km), replace as needed. Typically recommended annually.
Service Intervals Fluids
Brake Fluid Change:
Inspect fluid level and condition regularly. Typically recommended every 2-3 years or 30,000-45,000 miles (48,000-72,000 km).
Coolant Flush:
Initial flush at 105,000 miles (169,000 km) or 5 years, then every 75,000 miles (120,000 km) or 5 years thereafter. Consult manual for specific coolant type.
Fluid Specifications
Engine Oil Type:
SAE 5W-30 Synthetic (meeting GM specification GM6094M)
Engine Oil Capacity:
LS1: 4.5 quarts (4.3 L) with filter; LS2: 5.5 quarts (5.2 L) with filter
Coolant Type:
GM "Dex-Cool" 50/50 Extended Life Antifreeze/Coolant
Known Issues
Common Issues General:
Interior trim quality concerns, early models had some NVH (Noise, Vibration, Harshness) issues, potential for minor electrical glitches.
Common Issues Engine:
LS1 engines are generally robust; LS2 offers improved power. Potential for oil consumption in high-mileage engines. Coolant leaks from front timing cover/water pump area can occur.
Common Issues Drivetrain:
Tremec T-56 manual transmission is robust but can have occasional synchro wear or clutch hydraulic issues. Automatic transmissions are generally reliable but require proper fluid maintenance.
Common Issues Suspension:
Worn bushings and ball joints can develop over time due to spirited driving. Wheel bearing noise can be an issue.
📚 Vehicle History
Brand Heritage
Pontiac Heritage:
Pontiac was a performance-oriented division of General Motors, known for iconic models like the Firebird, Trans Am, and Bonneville. The GTO nameplate itself is a legendary muscle car icon from the 1960s.
Model Evolution
Reintroduction Context:
The GTO was revived for the 2004 model year, based on the Australian-market Holden Monaro coupe, a vehicle developed by GM's Holden subsidiary. It represented an attempt to capture the spirit of the original GTO with a modern, rear-wheel-drive platform.
Production
Production Location:
Elizabeth, South Australia, Australia (by Holden)
Production Years:
2004-2006
🏆 Awards & Recognition
Recognitions
Awards Nominations:
While not a heavy award-winner, it was praised for its performance value and V8 power, especially the LS2 models, as a modern interpretation of American muscle.
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