SECTION G - FUEL AND EXHAUST SYSTEMS
CAUTION:
HSV vehicles are equipped w ith a Supplemental Restraint System (SRS). An SRS consists of seat belt pre-
tensioners ( fit ted to all fron t seat s) , and a d riv er’s-sid e air bag or a driv er’s- side air b ag AND a passenger’s-
side air bag. Refer to CAUTIONS, Section 12M, of the Holden VX Series Service Information before
performing any service operation on or around S RS components, the steering mechanism or wiring. Failure
to follow the CAUTIONS could result in personal injury or unnecessary SRS system repairs.
PURPOSE
The purpose of this supplement is to provide information on the fuel and exhaust systems fitted to the HSV VX
models. This information is designed to supplement that given in the Holden VX Service Information, and details are
given where differences occur between the HSV models, and standard Holden models. A series of instruction
drawings detail the design changes and indicate specific part numbers, fitting instructions and relevant notes for
vehicle servicing.
NOTE:
If specific technical data on a HSV model is not contained in this supplement, obtain data for that model from the
relevant HSV or Holden VX Series Service Information.
CAUTION:
W hen hois ting (or j acking) HSV models, ens ure that the lifting head of the hoist lif ts on the chassis before the arm
of the hoist contacts the side-skirt
1. HSV EXHAUST SYSTEMS GENERAL INFORMATION.
The development of unique HSV Exhaust Systems has been necessitated by, and conducted in parallel with, the
development of engines and transmissions. A range of exhaust systems has been developed to satisfy the
demands for s pecific applic ations. Each developm ent has been designed to oper ate with a specific engine and has
been proven by extensive testing.
For VX the exhaust has been developed with different levels of refinement in mind. The first is a single outlet
exhaust, that produces a more subdued exhaust note, while another “sports” system has been developed to
produce a more sports oriented note, that still meets legal requirements. The design of the sports rear muffler is
similar to the straight through, low backpressure design used on GTS, although it has been retuned to provide
diff erentiation in the exhaust notes. All of these systems are com mon f rom the headers through to the interm ediate
muffler assembly. For GTS there is also a specific, low backpressure muffler design that also incorporates a
specific “double D” tailpipe to provide further differentiation.
Although HSV and Holden exhaust systems are different, the general principles are the same. Service notes
specified in relevant Holden Service Information Supplements provide useful information. Particularly, the
relationship between exhaust components and the clearances between exhaust components and the vehicle body
are im por tant. Inf ormation on the r elationship of HSV c omponents, torque s ettings and clear ances between exhaust
components and the body of the vehicle is presented in this section.
2. GTS 300, CLUBSPORT, R8, SENATOR AND GRANGE 255
EXHAUST SYSTEMS
2.1 GENERAL DESCRIPTION
Much of the exhaust system fitted to the HSV VX and W H models is carried over from VT 2. The main changes
have been in muf f ler design, to give the dual outlet spor ts m uf fler a m or e sporty note along with a new interm ediate
muffler design to inc or porate c ore vehicle c hanges to the pr opeller shaf t. The intermediate muf f ler now incorporates
a single balance pipe shorter, straight through mufflers and revised pipe work past the differential.
The new rear m uf f ler for Clubs port and R8 has the s am e appearance as for VT2, but a more distinctive note due to
a new str aight through design similar to that for GT S. This also has the benefit of a sm all power increase. Senator
and GTS have a revised appearance to suit the new VX shape.
For Grange models, the exhaust system is common with the SW B model up to the intermediate muffler, which is
150mm longer for LWB models, still using the same muffler elements. Grange models also require a new rear
muf fler, which uses the s ame m uffler elem ent as the part used on VT 2 Senators, but has a revised tailpipe, due to
the extra length in the rear section of the vehicle.
2.2 SERVICE OPERATIONS
When servicing the exhaust systems fitted to HSV VX vehicles, refer to figures G-1, G-2 and G-3 in the HSV VX
Service Inf ormation Supplem ent. These illustrations provide the necessary inform ation on the correct arrangem ent
of each component, torque settings, fitment clearances and alignment required.
3. XU-6 AND SENATOR 180i EXHAUST SYSTEMS.
3.1 GENERAL DESCRIPTION
The HSV exhaust system developed for the HSV VX Supercharged V6 model is based on the exhaust systems
developed for Senator 255 applications. Specific V6 extractors incorporating the two oxygen sensors are used,
along with a new for VX aluminium tail pipe extension. The engine pipes are the same as those used f or the HSV
VX LS1, except that the oxygen sensor holes in the engine pipes are sealed.
3.2 SERVICE OPERATIONS
W hen s ervicing the exhaust system s fitted to HSV VX Superchar ged vehicles, refer to f igures G-1, G-2 and G-3 in
the HSV VX Service Information Supplement. These illustrations provide the necessary information on the correct
arrangement of each component, torque settings, fitment clearances and alignment required.
4. HSV FUEL SYSTEMS GENERAL INFORMATION
All components of the fuel systems in HSV VX and W H, models are standard Holden components. It follows that
refer ence to the appr opriate section in the Holden Ser vice Inform ation is necessary when perform ing any servicing
operation on these components.
Section 8A – Fuel Tank of the VT Series I Service Information or
Section 8A - Fue l Tank of the VT Series II Service Information or
Section 8A – Fuel Tank of the WH Series Statesman and Caprice Service Information
LS1 EXHAUST HEADER RHS
FIGURE G-2
LS1 EXHAUST HEADER LHS
FIGURE G-3