SECTION G – FUEL AND EXHAUST SYSTEMS
CAUTION:
HSV vehicles are equipped with a Supplemental Restraint System (SRS). An SRS consists of seat belt pre-
tensioners (fit ted to all front seats), and a driver’s-side air bag or a d river’s-side air bag AND a passenger’s
side air bag. Refer to CAUTIONS, Section 12M, of the Holden VT Series I Service Information before
performing any service operation on or around SRS components, the ste ering 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 VT2 and
HSV VS models. This information is designed to supplement that given in the Holden VT2 and VS Series Service
Information, and details are given where differences occur between the HSV models, and standard Holden m odels. 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 m odel is not contained in this supplem ent, obtain data for that model f rom
the relevant HSV VT V8 or Holden VT series Service Manual Supplements.
CAUTION: When hoisting (or jacking) HSV models, ensure that the lifting head of the hoist lifts on the chassis before
the arm of the hoist contacts the side-skirt
1. HSV EXHAUST SYSTEMS GENERAL INFORM ATION
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
specific applications. Each development has been designed to operate with a specific engine and has been proven by
extensive testing.
For VT 2 the exhaust has been developed with diff erent levels of refinem ent in m ind. The firs t is a single outlet ex haust
com m on with VT 1, that produc es a m ore s ubdued exhaust note, while another “s ports” system has been developed to
produce a more sports oriented note, that still meets legal requirem ents. Both of these systems are comm on from the
headers through to the intermediate muffler assembly. For GTS there is also a specific, low backpressure muffler
design that also incorporates a specific aluminum extension.
Although HSV and Holden exhaust systems are different, the general principles are the sam e. Service notes specif ied
in relevant Holden Service Information provide useful information. Particularly, the relationship between exhaust
components and the clearances between exhaust com ponents and the vehicle body are important. Information on the
relationship of HSV components, torque settings and clearances between exhaust components and the body of the
vehicle is presented in this section.
2. GTS 300, CLUBSPORT, SENATOR AND GRANGE 250 EXHAUST SYSTEMS
2.1 GENERAL DESCRIPTION
Much of the exhaust system fitted to the HSV VT 2 and W H m odels is carried over from VT 1. The m ain change is in
the headers, which have been m odified to suit the new LS1 engine, and have also been modif ied to im prove the torque
and power character istic of the engine. The other changes f or VT 2 and G TS are the two new sports rear muf f lers . O ne
is standard on the ClubSport, R8 and SV99, and optional on other VT2 m odels with LS1. The other is available only on
GTS.
For Grange models, the exhaust system is common with the SWB model up to the intermediate muffler, which is
150mm longer f or LWB m odels, still us ing the same m uf fler elem ents. Gr ange models als o require a new rear m uff ler,
which uses the same muffler element as the part used on VT2 Senators, but has a revised tailpipe, due to the extra
length in the rear section of the vehicle.
2.2 SERVICE OPERATIONS
W hen servicing the exhaust systems fitted to HSV VT 2 vehicles, refer to Figure G-1, Figure G-2 and Figure G-3 in
this HSV VT2 Service Information Supplement. These illustrations provide the necessary information on the correct
arrangement 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 VT2 Supercharged V6 model is based on the exhaust systems
developed for Senator 250 applications. Specific V6 extractors incorporating the two oxygen sensors are used, along
with a unique aluminium tail pipe extension. The engine pipes are the same as those used for the HSV VT 1 LS1,
except that the oxygen sensor holes in the engine pipes are plugged.
3.2 SERVICE OPERATIONS
When servicing the exhaust systems fitted to HSV VT Supercharged vehicles, refer to Figure G-1, Figure G-2 and
Figure G-3 in the HSV VT V8 Service Information Supplement. These illus trations provide the nec essary inform ation
on the correct arrangement of each component, torque settings, fitment clearances and alignment required.
4. GRANGE 195i AND MALOO 195i EXHAUST SYSTEM S
4.1 GENERAL DESCRIPTION
With the introduction of the 195i engine on VS III Grange and Maloo, the opportunity was taken to improve the
refinement of the vehicle, while at the same time ensuring that there was not any loss in performance. This was
achieved by upgrading the muffler elements in the utility system from the small capacity mufflers used on previous
models, to a more up to date combination of parts.
The exhaust system now consists of tubular header, attached to a two into one connecting pipe via spherical type
flanges and gaskets. The rest of the exhaust system on the Grange is carry over, while the new intermediate muffler
assembly on the Maloo uses the VT style mufflers, and now has a larger volume rear muffler.
4.2 SERVICE OPERATIONS
When servicing the ex haust s ystem s f itted to HSV VS 195i vehicles , refer to Figure G-1, Figure G-2 and Figure G-3 in
the HSV VT Series I Service Information Supplement. These illustrations provide the necessary information on the
correct arrangement of each component, torque settings, fitment clearances and alignment required.
Note: For information on the exhaust system fitted to the HSV VT XU-8, see the relevant section of the HSV VT
V8 Service Information Supplement.
LS1 EXHAUS T HEADE R RHS
FI GURE G-2
LS 1 EXHAUST HEADE R LHS
FIGURE G-3
5. HSV FUEL SYSTEMS GENERAL INFORMATION
All components of the fuel systems in HSV VT 2, W H, supercharged V6, and VS III 195i models are standard Holden
com ponents. It follows that referenc e to the appropriate Section of the Holden Ser vice Inform ation below, is neces sary
when performing any servicing operation on these components.
Section 8A – Fuel Tank of the VT Series I Service Information or
Section 8A – Fuel Tank of the VT Series II Service Information or
Section 8A – Fuel Tank of the WH Series Statesman and Caprice Service Information or
Section 8A – Fuel Tank of the VS Series Service Information.