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 (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, 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.
PURPOSE
The purpos e of this s upplement is to pr ovide inform ation on the fuel and ex haust systems fitted to the HSV VT and
HSV VS models. This information is designed to supplement that contained in the Holden VT and VS Series
Service Information CD’s, and details are given where differences occur between the HSV models, and standard
Holden models . A s er ies of ins tr uc tion drawings detail the des ign c hanges and indicate s pec if ic part number s , 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 Holden VT or VS Series Service Inform ation CD. References are made throughout this section to Holden
VT and VS Series Service Information CD’s, to assist in providing information for specific service operations.
CAUTION:
W hen hois ting (or j acking) HSV models , ensure that the lifting head of the hoist lifts on the chas sis before the arm
of the hoist contacts the side-skirt
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 s pecific applic ations. Each developm ent has been designed to oper ate with a specific engine and has
been proven by extensive testing.
New HSV exhaust systems developed for VT models consist of two basic categories,
exhaust systems developed for 220 kw (5.7 litre) applications, and
exhaust systems developed for 195 kw (5.0 litre) applications.
Thes e two categories are sim ilar except specif ic rear m uff lers are optim ised f or each application. Also, within these
two categories, a variation to cater for the dif ferent wheelbase lengths of Sedans and Estates is provided: the f ront
pipes on the interm ediate m uff ler ass em bly are about 150 mm longer f or Es tate m odels. Other vehicles which c arry
over from the VS range retain the exhaust system developed for those vehicles. These applications are discussed
in the following paragraphs.
Although HSV exhaust systems and GMHA systems are different, the general principles are the same. Service
notes specified in this section of the Holden VT Series Service Information CD provide useful information.
Particularly, the relationship between exhaust components and the clearances between 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.
Limited clearance exists between the RHF Header attaching bolt and the power steering pump on the right hand
side of the engine. When removing this header, mounting bolts on the pump may need to be loosened and the
pump eased forward to provide additional clearance.
SENATOR AND GTS 220I EXHAUST SYSTEMS
GENERAL DESCRIPTION
HSV VT 220i Senator and GTS vehicles are fitted with a special exhaust system improved from the earlier 215i
HSV system. The major improvements in the 220 system are the incorporation of a larger rear muffler and freer
flowing tubular headers to lower back-pressure. The Senator Estate exhaust system is 150mm longer in the front
pipes of the intermediate muffler assembly. The 220 system comprises;
RH and LH tubular exhaust headers,
free-flow connecting pipes,
two large 1.8 litre catalytic converters,
free-flow intermediate mufflers and pipe assemblies,
a low restriction rear muffler assembly which incorporates a distinctive ‘twin-oval' shaped exhaust outlet.
SERVICE OPERATIONS
W hen servicing the exhaust systems fitted to HSV VT 220i GTS and Senator vehicles, refer to Figures G-1, G-2
and G-3. These illustr ations provide necessar y inform ation on the correct ar rangement of each c omponent, torque
settings, fitment clearances and alignment required.
SENATOR, MANTA AND CLUBSPORT 195I EXHAUST SYSTEMS
GENERAL DESCRIPTION
Senator, Club Sport and Manta 195i models are fitted with an exhaust system sim ilar to the 220 system described
above, except that the rear muffler is optimised for the 5.0 litre engine, and this muffler incorporates a single oval
shape tale pipe. Again, the system for the Senator 195i Estate is 150 mm longer in the front pipes of the
intermediate muffler assembly .
SERVICE OPERATIONS
When servicing the exhaust system s fitted to Senator, Manta and ClubSport 195i models , r ef er to Figures G-1,
G-2 and G-3. These illustrations provide the necessary information on the correct arrangement of each component,
torque settings, fitment clearances and alignment required.
GRANGE AND MALOO 185I EXHAUST SYSTEMS
GENERAL DESCRIPTION
Grange and Maloo vehicles are fitted with specific designed exhaust systems. The systems comprise RH and LH
tubular exhaust headers, free flow connecting pipes to a single catalytic converter, free flow intermediate muffler
and pipe assemblies, low restriction rear muffler assemblies and distinctive exhaust outlets.
SERVICE OPERATIONS
When servicing the Grange and Maloo exhaust systems, refer to Figures G-4 through to G-10, as appropriate.
These illustrations provide the necessary information on the correct arrangement of each component, torque
settings, fitment clearances and alignment required.
HSV FUEL SYSTEMS GENERAL INFORMATION
Specific HSV fuel injectors are fitted to all HSV VT and VS 5.7 litre vehicles. No service operations are performed
on these injectors - rather, the injectors are serviced by replacement. The part number of these HSV injectors is
06M6711901: injectors fitted to HSV VT and VS 5.0 litre engines are standard Holden components. Removal and
installation procedures are the same as the procedures used for the standard Holden injectors and therefore,
referenc e to the Holden VT Series Ser vice Inf or mation CD, Section 6C2-3 SERVICE OPERATIONS - V8 ENG INE
should be made as required.
The fuel pump fitted to HSV VS Grange 215i is a unique fuel pump fitted by HSV. The HSV replacement part
number for the pump is 08A-711901. Removal, installation and all other service operations on this pump are the
same as the procedures specified in the Holden VT Series Service Information CD, Section 8A FUEL TANK.
All other components of the fuel system in HSV VT and VS models ar e standar d Holden c omponents. It f ollows that
reference to the relevant Holden Series Service Information CD’s is necessary when performing any servicing
operation on these components.
HSV EXHAUST SYSTEM LAYOUT DIAGRAMS
The following illustrations detail the exhaust system layout, mounting points and clearance specifications for the
various Holden Special Vehicle models.
HSV VT 220I AND 195I EXHAUST SYSTEM
Figure G-1 Sheet 1 - HSV 220i And 195i VT Exhaust System
Figure G-1 Sheet 2 - HSV 220i And 195i VT Exhaust System
Figure G-2 - HSV 220i And 195i VT Exhaust System Clearances
Figure G-3 - HSV 220i And 195i VT Exhaust System Clearances
HSV GRANGE 215I EXHAUST SYSTEM
Figure G-4 - HSV Grange 215i Exhaust System
Figure G-5 - HSV Grange 215i Exhaust System Clearances
HSV GRANGE 185I EXHAUST SYSTEM
Figure G-6 - HSV Grange 185i Exhaust System
Figure G-7 - HSV Grange 185i Exhaust System Clearances
Figure G-8 - HSV Grange 185i Exhaust System Clearances
HSV MARLOO 185I EXHAUST SYSTEM
Figure G-9 - HSV Marloo 185i Exhaust System
Figure G-10 - HSV Marloo 185i Exhaust System Clearances