2005 Pontiac Montana Service and Repair Manual

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Factory-Grade Data

2005 Pontiac Montana service and repair manual — a detailed, factory-style reference for maintenance, diagnostics, and repair. Use it to confirm correct procedures, specifications, and system coverage before you start work.

Designed for technicians and DIY owners, this manual helps you diagnose issues correctly, follow proven repair steps, and use wiring diagrams and system sections to track faults faster.

What’s included

  • Step-by-step repair procedures and service information
  • Specifications and reference data (where provided)
  • Electrical diagnostics with wiring diagrams
  • Coverage across major systems: engine, transmission/driveline, brakes, steering, suspension, HVAC, and more

Trims covered

  • Base Mini Passenger Van 4-Door
  • SV6 Mini Passenger Van 4-Door

Engines covered

  • 3.4L 207Cu. In. V6 GAS OHV Naturally Aspirated
  • 3.5L 3498CC 213Cu. In. V6 GAS OHV Naturally Aspirated
  • 3.5L 213Cu. In. V6 GAS OHV Naturally Aspirated

Index / Table of contents

  • Body
  • Brakes
  • Chassis Electrical
  • Driveline
  • Engine Cooling
  • Engine Electrical
  • Engine Mechanical
  • Engine Performance & Emission Controls
  • Fuel System
  • General Information & Identification
  • Heating, Ventilation, & Air Conditioning
  • Hybrid & Electric Vehicle Systems
  • Steering
  • Suspension
  • Transmission, Clutch, & Transfer Case
  • Wiring Diagrams

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Vehicle Safety Data

2005 Pontiac Montana Recalls & Complaints

NHTSA #06V41700031/10/2006Component: AIR BAGS:FRONTAL

CERTAIN VEHICLES ORIGINALLY BUILT WITH CLOTH SEATS THAT WERE EQUIPPED WITH AN AUTOMATIC AIR BAG PASSENGER SENSING SYSTEM AND LATER REUPHOLSTERED WITH AFTERMARKET LEATHER SEAT COVER KITS ARE INVOLVED.

Consequence

IF THE PASSENGER SENSING SYSTEM MALFUNCTIONS, THE FRONT AIR BAG ON THE PASSENGER SIDE MAY BE DISABLE

Remedy

BECAUSE A REPLACEMENT LEATHER SEAT COVER THAT IS COMPATIBLE WITH THE PASSENGER SENSING SYSTEM IS NOT

NHTSA #04V59700022/12/2004Component: LATCHES/LOCKS/LINKAGES:DOORS:LATCH

ON CERTAIN MINIVANS EQUIPPED WITH SECOND-ROW BUCKET SEATS OR CAPTAIN'S CHAIRS AND A POWER SLIDING DOOR ON THE PASSENGER SIDE OF THE VEHICLE, A PASSENGER USING THE INTERIOR HANDLE TO OPEN THE POWER SLI

Consequence

IF A PASSENGER USES THE INTERIOR HANDLE TO OPEN THE POWER SLIDING DOOR AND HOLDS ONTO THE HANDLE WHI

Remedy

DEALERS WILL REPLACE THE POWER SLIDING DOOR INTERIOR HANDLE ON THE PASSENGER-SIDE. IF THE VEHICLE I

NHTSA #05V28700020/06/2005Component: PARKING BRAKE

CERTAIN SPORT UTILITY VEHICLES FAIL TO CONFORM TO THE REQUIREMENTS OF FEDERAL MOTOR VEHICLE SAFETY STANDARD NO. 135, 'PASSENGER CAR BRAKE SYSTEMS.' TO MEET THE STANDARD, THE VEHICLE MUST NOT MOVE FOR

Consequence

WHEN THE PARKING BRAKE IS RELEASED, THE DRIVER MAY NOTICE UNINTENDED BRAKING WHEN ACCELERATING, DECE

Remedy

DEALERS WILL INSPECT FOR PARKING BRAKE LEVER SLIPPAGE AT EACH REAR BRAKE CALIPER AND REPLACE THE CAL

NHTSA #10V11000019/03/2010Component: SUSPENSION:REAR

THE BRAUN CORPORATION HAS NOTIFIED NHTSA ABOUT A DEFECT IN CERTAIN MODEL YEAR 2005-2008 GENERAL MOTORS MOBILITY CONVERSION, HANDICAPPED ACCESSIBLE LOW FLOOR MINIVANS. DURING CONVERSION, THE DRIVER OR

Consequence

A SQUEAKING OR CLUNKING NOISE MAY DEVELOP. THE TRAILING ARM BUSHINGS MAY PREMATURELY WEAR AND THE T

Remedy

DEALERS WILL INSPECT AND WILL HAVE A SUPPLY OF RETROFIT PARTS AVAILABLE TO REMEDY THE VEHICLES FREE

NHTSA #05V06100018/02/2005Component: SEATS:MID/REAR ASSEMBLY

ON CERTAIN MINIVANS, THE OUTBOARD RELEASE HANDLE ON THE IMPACT-SIDE SECOND-ROW BUCKET SEAT MAY BE ACTUATED AND THE REAR LATCHES MAY UNLATCH EARLY IN A SIDE IMPACT CRASH. THIS WAS DISCOVERED IN A SID

Consequence

IF THE REAR LATCHES OF THE SEAT RELEASE EARLY IN A SEVERE SIDE IMPACT, THE FRONT OUTBOARD LATCH MAY

Remedy

DEALERS WILL REMOVE THE SEAT LATCH RELEASE HANDLE AND INSTALL A BLACK PLASTIC CAP OVER THE EXPOSED M

NHTSA #09E00500017/02/2009Component: STEERING

DORMAN IS RECALLING 979 STEERING KNUCKLES, DORMAN P/NOS. 697-902 AND 697-903, SOLD UNDER DORMAN'S "OE SOLUTIONSTM" BRAND NAME, AND NAPA P/NOS. 7-8502 AND 7-8503 WHICH WERE SOLD FOR REPLACEM

Consequence

A BROKEN STEERING KNUCKLE COULD RESULT IN LOSS OF STEERING CONTROL AND A POSSIBLE CRASH WITHOUT WARN

Remedy

DORMAN WILL NOTIFY OWNERS AND REPLACE THE DEFECTIVE STEERING KNUCKLES FREE OF CHARGE AND REIMBURSE T

TSB #11027947

This PI directs technician to training regarding sliding door operation.

TSB #11020816

This PI communicates the requirement to provide a pico file to receive diagnostic assistance from TAC.

TSB #11019074

This Preliminary Information communication provides information to the technician about the use of J-35616-64B and Mini 50 terminal test probe, replacement terminals, and terminated leads.

TSB #11019073

This Preliminary Information communication provides information to the technician about the use of J-35616-64B and Mini 50 terminal test probe, replacement terminals, and terminated leads.

TSB #11019072

This Preliminary Information communication provides information to the technician about the use of J-35616-64B and Mini 50 terminal test probe, replacement terminals, and terminated leads.

TSB #11014455

This Preliminary Information communication provides information to the technician about vehicles that have an unusual noise and is difficult to identify, isolate or pinpoint. Technician should get record a sound clip or take a video of the

TSB #11009156

This Preliminary Information communicates to the dealer the process for downloading or updating operating software for the Tire Pressure Monitor, Active Fuel Injector tester, multi media tester, PICO Scope, GR8 starting/charging tester and

TSB #11008956

This service bulletin provides information for dealers/technicians on When and How to Submit a Field Product Report (FPR) (U.S. and Canada Dealers Only).

Showing the 8 most recent of 567 technical service bulletins on file with NHTSA.

20110330Component: AIR BAGS:FRONTALCrash reported3 injured

TL* THE CONTACT OWNS A 2005 PONTIAC MONTANA. THE CONTACT WAS DRIVING APPROXIMATELY 60 MPH AND CRASHED INTO A DEER. THE AIR BAGS DID NOT DEPLOY AND THERE WAS DAMAGE TO THE HOOD, HEAD LIGHTS, FENDER AND

20120605Component: SEATSCrash reported2 injured

TL* THE CONTACT OWNS A 2005 PONTIAC MONTANA. THE CONTACT STATED THAT THE DRIVER WAS TRAVELING 10 MPH WHEN ANOTHER VEHICLE CRASHED INTO THE DRIVER'S SIDE REAR OF THE VEHICLE, CAUSING IT TO GO INTO A TA

20120605Component: SEAT BELTSCrash reported2 injured

TL* THE CONTACT OWNS A 2005 PONTIAC MONTANA. THE CONTACT STATED THAT THE DRIVER WAS TRAVELING 10 MPH WHEN ANOTHER VEHICLE CRASHED INTO THE DRIVER'S SIDE REAR OF THE VEHICLE, CAUSING IT TO GO INTO A TA

20120605Component: AIR BAGSCrash reported2 injured

TL* THE CONTACT OWNS A 2005 PONTIAC MONTANA. THE CONTACT STATED THAT THE DRIVER WAS TRAVELING 10 MPH WHEN ANOTHER VEHICLE CRASHED INTO THE DRIVER'S SIDE REAR OF THE VEHICLE, CAUSING IT TO GO INTO A TA

20050906Component: VEHICLE SPEED CONTROLCrash reported1 injured

DT: THE CONTACT OWNS A 2005 PONTIAC MONTANA. THE CONTACT STATED WHILE DRIVING THE VEHICLE IT ACCELERATED, CAUSING IT TO CRASH INTO A TREE. SHE WAS DRIVING SLOWLY DOWN A DRIVEWAY. BYSTANDERS STA

Showing the 5 most serious of 130 complaints filed with NHTSA.

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