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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), a driver’s-side air bag, a passenger’s-side air bag,and left and right side
airbags. Refer to CAUTIONS, Section 12M, of the Holden WK 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 unnecessary SRS system repairs.
1 Purpose................................................................................................................................................... 2
2 Exhaust System General Information.................................................................................................. 3
2.1 Grange 285 Exhaust System.................................................................................................................................3
General Description...............................................................................................................................................3
Service Operations.................................................................................................................................................3
3 Fuel System General Information ........................................................................................................ 4
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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 WK model.
This information is designed to supplement that given in the Holden WK 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 WK 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 System 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 WK the exhaust has been developed with different levels of refinement in mind. The 285 kW ‘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 bee retuned to provide differentiation
in the exhaust notes. All of these systems are common from the headers to the intermediate muffler assembly.
For WK there is also a specific low backpressure muffler design, which incorporates a machined alloy 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 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.
2.1 Grange 285 Exhaust System
General Descript i on
Much of the exhaust system fitted to the HSV WK models is carried over from VY 2, using a larger diameter header system
for primary and secondary pipes, and a larger diameter pipe on the converter. Also, there has been a change in muffler
design, to give the dual outlet sports muffler a more sporty note along wi th 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.
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 VY2 Senators, but has a revised tailpipe, due to the extra length in the rear
section of the vehicle.
Service Operations
When servicing the exhaust systems fitted to HSV WK vehicles, refer to Drawing 08I-030003.
NOTE
The exhausts on HSV WK model before 17/10/03 are
fitted with an exhaust alignment shim. If the RH
header (Part No. 08C030602) requires replacement
for any reason it will be replaced by the later version
header (Part No. 08C030608). If the later version
header (Part No. 08C030608) is used the exhaust
alignment shim will no longer be required.
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3 Fuel System General Information
All components of the fuel systems in HSV WK 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.
Refer Section 8A1 Fuel Tank of Holden WK Service Information.
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CAT. CONVERTER LHS
08C-030603
HEADER LHS
08C-030602
HEADER RHS
08C-030601
CAT. CONVERTER
08C-030604
INTERMEDIATE MUFFLER ASM
08C-001801 (LWB)
REAR MUFFLER ASM.
08C-031301
CLAMP (60mm)
08C-651907
DATE REVISION RECORD
SYM DR.
AUTH'Y CK.
-
DWG.
DATE:
2. 8. 03
D.P
CKH
WK
-
EXHAUST SYSTEM
WK
08I-030003
INSTRUCTION DRAWING.
J. O.