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Section G
Fuel And Exhaust Systems
ATTENTION
HSV vehicles are equipped with a Supplemental Restraint System (SRS). An SRS consists of seat belt pre-
tensioners (fitted to all front seats), and a driver’s-side air bag or a driver’s-side air bag AND a passenger’s-
side air bag. Refer to CAUTIONS, Section 12M of the Holden VY Series Service Information before performing
any service operation on or around SRS components, the steering mechanism or wiring. Failure to follow the
CAUTIONS could result in personal injury or unnecessar y SRS system repairs.
1 Purpose................................................................................................................................................... 2
2 Exhaust Systems General Information................................................................................................ 3
3 GTS 300, Clubsport, R8 and Senator 260 Exhaust Systems............................................................. 4
3.1 General Description ...............................................................................................................................................4
3.2 Service Operations.................................................................................................................................................5
4 Fuel Systems General Information .................................................................................................... 10
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1 Purpose
The purpose of this supplement is to provide information on the fuel and exhaust systems fitted to the HSV VY models.
This information is designed to supplement that given in the Holden VY Series 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 VY
Series Service Information Supplements.
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
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2 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
specific applications. Each development has been designed to operate with a specific engine and has been proven by
extensive testing.
For VY the exhaust has been developed with different levels of refinement in mind. The standard 260kW “sports” system
has been developed to produce a 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
differentiation in the exhaust notes. All of these systems are common 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
“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 Manual Supplements provide useful information. Particularly, the relationship between exhaust
components and the clearances between exhaust components and the vehicle body are important. Information on the
relationship of HSV components, torque settings and cle aran ces betw een ex haust components and the body of the
vehicle is presented in this section.
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3 GTS 300, Clubsport, R8 and
Senator 260 Exhaust Systems
3.1 General Description
Much of the exhaust system fitted to the HSV VY models is carried over from VT 2. The main changes have been in
muffler design, to give the dual outlet sports muffler a sportier note along with a new intermediate muffler design to
incorporate core vehicle changes to the propeller shaft. The intermediate muffler now incorporates a single balance pipe
shorter, straight through mufflers and revised pipework past the differential.
The new rear muffler for Clubsport and R8 has the same appearance as for VX, but a more distinctive note due to a new
straight through design similar to that for GTS. This also has the benefit of a small power increase. GTS has a revised
appearance to suit the new VY shape. 260kW powered vehicles also have a new dual alloy tip.
For Grange models, the exhaust system is common with the SWB 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 muffler, 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.
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3.2 Service Operations
When servicing the exhaust systems fitted to HSV VY vehicles, refer to Drawings 08I-020001, 08I-020002, 08I-020003,
08I-020004. These illustrations provide the necessary information on the correct arrangement of each component, torque
settings, fitment clearances and alignment required.
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4 Fuel Systems General
Information
All components of the fuel systems in HSV VY, models are standard Holden components. It follows that reference to the
appropriate Holden Service Information Supplement is necessary when performing any servicing operation on these
components.
Section 8A – Fuel Tank of the VT Series 1 Service Information or
Section 8A - Fuel Tank of the VT Series 11 Service Information.