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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 (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: PDF 📖 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: PDF 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,...
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Pontiac GTO 2004-2006 Service & Repair Manual
🏷️ 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:
PDF
📖 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:
PDF
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.
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