Fuel And Exhaust Systems Page G-1
Page G-1
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), a driver’s-side air bag , a passenger’s-side air bag and left and right side
airbags. Refer to CAUTIONS, Section 12M, in Volume 7 of the Holden VYII series Service Manual before
performing any service operation on or around SRS components, the eering mechanism or wiring. Failure to
follow the CAUTIONS could result in personal injury or unnecessary SRS system repairs.
1 Purpose...............................................................................................................................................G-2
2 HSV Exhaust Systems General Information....................................................................................G-3
3 GTS 300, Clubsport, R8 And Senator 285 Exhaust Systems.........................................................G-4
3.1 General Description........................................................................................................................................... G-4
3.2 Service Operations ............................................................................................................................................ G-5
4 HSV Fuel Systems General Information ..........................................................................................G-9
Fuel And Exhaust Systems Page G-2
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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 VYII models. This
information is designed to supplement that given in the Holden VY 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 VYII series
Service Manual 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
Fuel And Exhaust Systems Page G-3
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2 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
specific applications. Each development has been designed to operate with a specific engine and has been proven by
extensive testing.
For VYII the exhaust has been developed with different levels of refinement in mind. The standard 285kW “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 clearances between exhaust components and the body of the vehicle is
presented in this section.
Fuel And Exhaust Systems Page G-4
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3 GTS 300, Clubsport, R8 And
Senator 285 Exhaust Systems
3.1 General Description
The VYII exhaust system has new larger diameter pipe extractors connecting to a larger diameter inlet to the catalytic
convertor.The spherical joint between the extractor and the connecting pipe has been dispensed with. The rest of the exhaust
system carries over from VY.
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3.2 Service Operations
When servicing the exhaust systems fitted to HSV VYII vehicles, refer to Drawings 08I-030004, 08I-030005,
08I-030006. These illustrations provide the necessary information on the correct arrangement of each component, torque
settings, fitment clearances and alignment required.
Fuel And Exhaust Systems Page G-6
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DATE
ISSUE DATED
AUTH'Y
CK.
SYM
AUTH'Y
RELEASE
REVISION RECORD
DATE
SYM
SIGNATURES ON
ORIGINAL APPROVAL
DR.
14.07.00
ADVANCED AUTOMOTIVE DESIGN AND ENGINEERING
08I-030004
08C-030601
INSTRUCTION DRAWING.
A4
SIZE
EXHAUST
HEADER (LH)
REVISION RECORD
PRELIMINARY ISSUE
CK.
NAME
PART NO.
CK.
REFERENCE
DWG.
DR.
DATE:
APPR
APPR
DR.
11.11.03
AP
DP
JO
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Fuel And Exhaust Systems Page G-8
Page G-8
REAR MUFFLER ASM.
advanced automotive design and engineering
DATE
PARTNO.
NAME
REVISION RECORD
SYM
ORIGINAL APPROVAL
ISSUE DATED
SIGNATURES ON
DR.
AUTH'YCK.
APPR
APPR
-
MODEL :
REFERENCE :
DWG.
CK.
DATE:
DR.
12.11.03
D.P
AP
JO
VYII
-
EXHAUST SYSTEM
SEDAN - VYII
08I-030006
advanced automotive design and engineering
INSTRUCTION DRAWING.
A4
SIZE
RELEASE -
CAT. CONVERTER LHS
08C-030603
HEADER LHS
08C-030601
HEADER RHS
08C-030608
CAT. CONVERTER
08C-030604
INTERMEDIATE MUFFLER ASM
08C-000301
ALLOY TIPS
TIPS 08C-020603 X2
RIVETTS 77B-020002 X6
(ALL MODELS
EXCEPT GTS
AND MALOO)
SWB - 285 kW
08C - 020601
SWB - 300 kW
08C - 020701
CLAMP (60mm)
08C-651907
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4 HSV Fuel Systems General
Information
All components of the fuel systems in HSV VYII models are standard Holden components. It follows that reference to the
appropriate Holden Service Manual Supplement is necessary when performing any servicing operation on these components.
Section 8A – Fuel Tank of the VY Series 1 Service Information
or
Section 8A - Fuel Tank of the VY Series 11 Service Information