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Pontiac GTO 2004-2006 Service & Repair Manual
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Basic Information Identification Make: Pontiac Model: GTO Year Range Covered: 2004-2006 Codes Vehicle Platform: GM Zeta Platform (specifically modified for Holden Monaro/Pontiac GTO) Transmission Codes Common: M12 (6-speed manual), 4L60-E...
Type: Cars
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Sku: 424895
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| Basic Information | |
| Identification | |
| Make: | Pontiac |
| Model: | GTO |
| Year Range Covered: | 2004-2006 |
| Codes | |
| Vehicle Platform: | GM Zeta Platform (specifically modified for Holden Monaro/Pontiac GTO) |
| Transmission Codes Common: | M12 (6-speed manual), 4L60-E (4-speed automatic) |
| Engine Codes Common: | LS1 (5.7L V8), LS2 (6.0L V8) |
| Introduction | |
| Market Position | |
| Segment: | Performance Sedan/Coupe, Muscle Car Revival |
| Target Audience: | Enthusiasts, DIY mechanics, owners of the 2004-2006 Pontiac GTO |
| Competitive Analysis | |
| Competitors Era: | Ford Mustang, Chevrolet Camaro (earlier generations), Dodge Charger (later generations), Nissan 350Z, Mitsubishi Lancer Evolution |
| Key Features | |
| Design Origin: | Rebadged Australian Holden Monaro |
| Powertrain Focus: | Rear-wheel drive, V8 engine performance |
| Manual Value Proposition: | Empowers owners with factory-level repair knowledge, saves on labor costs, enhances vehicle longevity |
| Manual Details | |
| Coverage Areas | |
| General Coverage: | Comprehensive service and repair for all GTO models 2004-2006 |
| Page Count | |
| Estimated Page Count: | Hundreds of pages (exact number not specified, but described as extensive) |
| Manual Type | |
| Type: | Factory Service Repair Manual |
| Language | |
| Language: | English |
| Format | |
| Format: | |
| Manual Coverage | |
| Systems Covered | |
| Engine Mechanical: | Engine assembly, disassembly, cylinder heads, pistons, crankshaft, camshaft, timing, lubrication system |
| Engine Performance: | Fuel injection, ignition system, emissions control, cooling system, starting and charging systems |
| Transmission Manual: | Clutch, gearbox, shifter mechanism, overhaul, repair |
| Transmission Automatic: | Torque converter, transmission control module (TCM), valve body, internal components, overhaul, repair |
| Drivetrain: | Driveshaft, differential, axles, CV joints |
| Suspension: | Front and rear suspension components, alignment, shock absorbers, springs, bushings |
| Steering: | Power steering system, steering column, steering rack, linkages |
| Brakes: | Brake system components (calipers, rotors, pads, lines, master cylinder), ABS, parking brake |
| Electrical System: | Wiring diagrams, battery, alternator, starter, lighting system, power accessories |
| Body And Frame: | Body panels, doors, hood, trunk, glass, interior trim, structural components |
| HVAC: | Heating, ventilation, and air conditioning system components, refrigerant, diagnostics |
| Infotainment And Controls: | Audio system, climate controls, instrument cluster, dashboard |
| Procedures Included | |
| Routine Maintenance: | Oil changes, filter replacements, fluid checks and top-offs, tire rotation |
| Troubleshooting: | Diagnostic procedures, common problem identification, fault code interpretation |
| Component Removal And Installation: | Step-by-step guides for replacing major and minor components |
| Engine Rebuild: | Detailed instructions for complete engine disassembly and reassembly |
| Transmission Overhaul: | Detailed instructions for manual and automatic transmission rebuilds |
| Brake Service: | Pad and rotor replacement, caliper service, bleeding procedures |
| Suspension And Steering Service: | Component replacement, alignment specifications |
| Electrical Diagnostics: | Troubleshooting electrical faults using wiring diagrams and diagnostic tools |
| HVAC Service And Recharge: | System leak testing, refrigerant evacuation and recharge |
| Technical Depth | |
| Depth: | Comprehensive (from basic maintenance to complete component overhauls and diagnostics) |
| Illustrations: | Hundreds of illustrations to aid in repairs |
| Searchability: | Searchable PDF functionality |
| Factory Knowledge: | Covers procedures and knowledge as held by factory-trained technicians |
| Manual Specifications | |
| File Format | |
| File Type: | |
| Printability: | Printable pages |
| Print Quality | |
| Quality: | Great quality service manual |
| Binding Type | |
| Binding: | N/A (Digital PDF format) |
| Paper Type | |
| Paper Type: | N/A (Digital PDF format) |
| Engine Specifications | |
| Primary Engine | |
| Engine 2004: | LS1 5.7L V8 |
| Engine 2005 2006: | LS2 6.0L V8 |
| Performance Ls1 | |
| Horsepower Ls1: | 350 hp @ 5200 rpm |
| Torque Ls1: | 365 lb-ft @ 4000 rpm |
| Performance Ls2 | |
| Horsepower Ls2: | 400 hp @ 6000 rpm |
| Torque Ls2: | 395 lb-ft @ 4400 rpm |
| Fuel System | |
| Injection Type: | Sequential Fuel Injection (SFI), Multi-port Fuel Injection (MPFI) |
| Fuel Type: | Premium Unleaded Gasoline (91 octane or higher recommended) |
| Cooling System | |
| Coolant Type: | Dex-Cool (Orange long-life coolant), or equivalent silicate-free, phosphate-free, borate-free, nitrite-free, nitrITE-free OAT coolant |
| Lubrication System | |
| Oil Type: | SAE 5W-30 (Synthetic recommended for optimal performance and protection) |
| Oil Capacity Ls1: | 5.5 quarts (with filter change) |
| Oil Capacity Ls2: | 7.0 quarts (with filter change) |
| Transmission | |
| Standard | |
| Standard Transmission 2004: | M12 Tremec T-56 6-speed Manual |
| Standard Transmission 2005 2006: | TR-6060 6-speed Manual (updated version of Tremec T-56) |
| Optional | |
| Optional Transmission: | 4L60-E 4-speed Automatic |
| Features | |
| Manual Transmission Fluid: | GM Synchromesh Friction Modified (or equivalent Dexron III/Mercon ATF for some components) |
| Automatic Transmission Fluid: | Dexron III/Mercon ATF |
| Dimensions | |
| Exterior | |
| Wheelbase: | 109.8 inches |
| Length: | 194.1 inches |
| Width: | 72.4 inches |
| Height: | 55.1 inches |
| Weights | |
| Curb Weight Manual: | ~3737 - 3850 lbs (depending on year and options) |
| Curb Weight Automatic: | ~3850 - 3950 lbs (depending on year and options) |
| Wheels And Tires | |
| Wheel Size: | 17-inch standard, 18-inch optional |
| Tire Size Standard: | P225/50R17 (front), P245/45R17 (rear) |
| Tire Size Optional: | P235/40R18 (front), P265/35R18 (rear) |
| Bolt Pattern: | 5x120 mm (5x4.72 inches) |
| Center Bore: | 69.4 mm (for factory wheels) |
| Safety Features | |
| Ratings | |
| NHTSA Frontal Crash Rating: | 5-star (Driver and Passenger) |
| IIHS Front Offset Crash Rating: | Good (for models tested) |
| Active Features | |
| ABS: | Standard Anti-lock Braking System (ABS) |
| Traction Control: | Traction Control System (TCS) - standard on most models |
| Stability Control: | Electronic Stability Control (ESC) - introduced on later models, check specific year/trim |
| Passive Features | |
| Airbags: | Frontal airbags (driver and passenger), optional side airbags |
| Seatbelts: | 3-point inertia-reel seat belts with pretensioners |
| Technology Features | |
| Infotainment | |
| Audio System: | Standard AM/FM/CD player with optional premium sound system (e.g., Pioneer), some models featured subwoofer. |
| Instrument Cluster: | Analog gauges, tachometer, speedometer, fuel gauge, coolant temperature gauge, driver information center (DIC) on some trims. |
| Driver Assistance | |
| Cruise Control: | Standard cruise control system. |
| Parking Sensors: | Not typically available on this generation. |
| Connectivity | |
| Auxiliary Input: | Generally not standard, aftermarket solutions often used. |
| Bluetooth: | Not standard, available through aftermarket integration. |
| Maintenance | |
| Service Intervals | |
| Oil Change Interval: | Every 7,500 miles or 6 months, whichever comes first (using synthetic oil recommended by manual). |
| Tire Rotation Interval: | Every 7,500 miles |
| Transmission Fluid Change Interval Auto: | Every 50,000 - 100,000 miles (check manual for specific recommendations based on driving conditions) |
| Transmission Fluid Change Interval Manual: | As needed or every 100,000 miles (check manual) |
| Coolant Flush Interval: | Every 5 years or 100,000 miles (for Dex-Cool) |
| Fluid Specifications | |
| Brake Fluid Type: | DOT 3 (or DOT 4 for some applications, verify with manual) |
| Power Steering Fluid Type: | Dexron III/Mercon ATF |
| Known Issues | |
| Clutch Release Bearing Noise: | Characteristic 'clatter' or 'whirring' noise from the clutch release bearing, especially when the clutch pedal is depressed. |
| Interior Rattles: | Some owners report various interior rattles and creaks due to panel fitment or materials. |
| Exhaust Manifold Leaks: | Exhaust manifold gaskets can sometimes fail, leading to an exhaust leak and ticking sound. |
| Blower Motor Resistor: | The blower motor resistor can fail, causing the HVAC fan to only work on the highest setting. |
| Oil Pan Gasket Leaks: | Occasionally, oil pan gaskets can develop leaks, particularly at higher mileage. |
| Vehicle History | |
| Brand Heritage | |
| Pontiac Legacy: | Pontiac's history as GM's performance brand, known for iconic models like Firebird and Trans Am. |
| Model Evolution | |
| Reintroduction Context: | Revival of the GTO nameplate, drawing on its muscle car heritage. |
| Australian Roots: | Based on the Holden Monaro, a highly regarded Australian sports coupe. |
| Year Updates 2005: | Introduction of the larger 6.0L LS2 V8 engine. |
| Production | |
| Manufacturing Location: | Adelaide, Australia (by Holden) |
| Production Years: | 2004-2006 |
| Sales Performance General: | Sales started strong but declined, leading to discontinuation. |
| Awards & Recognition | |
| Recognitions | |
| Car And Driver 10Best: | Included in Car and Driver's 10Best list for 2004. |
| Motor Trend Car Of The Year: | Competed for MotorTrend Car of the Year, though not a winner. |
| Ratings | |
| General Perception: | Praised for its potent V8 engine and performance capabilities, but criticized for styling and interior refinement compared to competitors. |