SECTION E – ENGINES
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 supplem ent is to provide infor mation on the various engine pac kages fitted to the HSV VT and
HSV VS models. This information is designed to supplement that given 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 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 Holden VT or VS Series Service Information CD’s. References are made throughout this section to the
Holden 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
1. GENERAL INFORMATION
The development of engines by HSV has been an ongoing process for many years. Generally, HSV engine
development have been directed at the performance, competition and luxury segments of the market. Engine
developments are continually refined and incorporated in new projects such as the 220 kw engine developments.
As a consequence, engines are continually updated, remain competitive, and are developed for specific
applications. Eac h engine projec t is proven by extensive testing, in var ying environmental conditions , at several test
locations throughout Australia. HSV now has a range of engines to satisfy customer demands extending from luxury
sedans to performance and competition type vehicles. Although these various engines may be fitted with unique
HSV components (such as crankshaft, camshaft, pistons, valve train and the like), assembly procedures, torque
settings, engine diagnosis, valve tim ing procedures and other parameters are the same as for the standard GMHA
product unless stated otherwise in this Supplement. The various HSV engines are discussed in the following
paragraphs.
Engine Dress Covers.
All HSV VT V8 engines are fitted with a set of decorative engine dress covers. A distinctive set of HSV designed
covers encase the fuel rails, throttle body and rockers on each engine. Covers include HSV badges and decals
recessed into the surf ace material of the cove Specific colours are used on the dress covers f or each HSV engine
size, and the identify ing part numbers (and colours) of these covers are as follows:
HSV 195i VT Engines Flame Red
06M-970301B7 COVER ASM-FUEL RAIL RHS
06M-970302B7 COVER ASM-FUEL RAIL LHS
06N-970302B7 COVER ASM THROTTLE BODY
06X-121904B7 COVER ASM VALVE ROCKER LHS
06X-511901B7 COVER ASM VALVE ROCKER RHS
HSV 220i VT Engines Atlas Grey
06M-970301RY COVER ASM-FUEL RAIL RHS
06M-970302RY COVER ASM-FUEL RAIL LHS
06N-970302RY COVER ASM THROTTLE BODY
06X-121904RY COVER ASM VALVE ROCKER LHS
06X-511901RY COVER ASM VALVE ROCKER RHS
Engine Air Induction System.
HSV VT models are fitted with an Engine Air Induction System that incorporates several HSV spec ific co mponents.
Apart from the HSV designed Cold Air Intake System, the air induction system also incorporates a HSV designed
airbox and a spec ific Mass Air Flow (MAF) Sensor. Dif ferent Airbox sens or combinations are f itted to 220 engines.
Both engine variations use the standard Holden filter element and Intake Air Temperature (IAT) Sensor. Service
requirements for the filter are described in the relevant Holden Service Manual Supplement; no field service
adjustm ent is necess ary or possible on the MAF s ensor The HSV airbox is remo ved by gently pulling the box in a
vertical direction to release the locating stud from the integral grommets. The general arrangement of the HSV
Engine Air Induction System, together with HSV replacement part numbers, is shown in Figure E-1.
Figure E-1 - HSV Air Induction System
Specific HSV Engine Components.
Two spec ific HSV com ponents warrant special m ention in this supplem ent because technic al data is not contained
in servicing docum ents available to owners and engine repair facilities. T hese two components are a special valve
spring seat (HSV PN 06A-211902) and the special-to-type camshafts fitted to HSV engines. The hardened valve
spring seat, which is about 0.8 mm thick, prevents the valve spring from wearing the softer cast iron head:
irreparable damage to the head may result if this seat is not fitted. Also, several camshaft types have been
manufactured and fitted to GMHA V8 engines during the past decade. HSV engines are fitted with specific
camshafts and to help with the identification/diagnosis of cam shafts and engine problem s, the following details are
supplied:
HSV Camshaft Part No 06X-211907 06X-970301
HSV Engine kw Type 215 195 and 220
Lobe lift 0.28’’ 0.28’’
Lobe duration - intake
exhaust 268°
268°268°
268°
Valve Timing at
0.050’’ valve lift
intake-open
close
exhaust-open
close
21° BTDC
67° ABDC
65° BBDC
23° ATDC
21° BTDC
67° ABDC
65° BBDC
23° ATDC
Duration @ 0.050’’ 206°206°
2. SENATOR AND GTS 220i
GENERAL DESCRIPTION
The engine package fitted to 220i Senator and GTS vehic les is a HSV developm ent bas ed on the existing Holden 5
litre engine. The c apac ity of the engine is incr eased by a new cranks haf t which inc reas es the s tro k e to 88.4mm and
which, together with the pre-existing bore of 101.4 mm, provides a displacement of 5.7 litres. Specific design
pistons give a compression ratio of 8.55:1. Changes to the camshaft, camshaft drive, cylinder heads, pistons,
throttle body and engine m icr o proc es sor c ombine to develop 220k W of power at 4800 rpm and 475Nm of torque at
3600 rpm.
SERVICE OPERATIONS
The HSV 220i engine fitted to GTS and Senator models is to be serviced in accordance with the procedures
detailed in the Holden VT series Service Manual. The Throttle Body (PN 06N-970701) fitted to all HSV VT 220i
models is diff er ent to the throttle bodies fitted to smaller HSV engines . The 220i throttle body, which is stam ped ‘SV’
in blue ink, provides immediate response to an increase in throttle opening whereas the smaller body response is
more progressive. Service procedures on the 220i throttle body are the same as those detailed in the Holden VT
Series Service Information CD, (refer Section 6C2-3 SERVICE OPERATIONS), except that the initial throttle
opening will be larger on 220i engines (when com par ed to 195i engines) to obtain the s pecif ied engine idle RPM. In
addition, HSV VT 220i Senator and GTS vehicles are fitted with specific HSV design ECM/PCM to control the
engine management system. The ECM/PCMs are fitted with specific Mem-Cals to suit the 220i engine assembly.
Both the ECM/PCM's and Mem-Cals can be identified and serviced by the part numbers in the following chart.
ECM/PCM MEMCAL
DELCO ID HSV SERVICE DELCO ID HSV SERVICE
P/N B/C P/N P/N P/N
220 MANUAL ECM 16268318 CFZF 12F-970701 16268260 12F-970708
220 AUTO PCM 16268308 CFZD 12F-970702 16268253 12F-970704
ENGINE ASSEMBLY – SERVICE
Specific HSV components and assemblies have been included in the 220i engine The part number for these
replacement service components and assemblies are detailed in the table below.
Part Number Description
06A2970301 Head Assembly -Cylinder
06A-211902 Seat -Valve Spring
06C-970701 Crankshaft 5.7 litres
06C3711901 Fly wheel and Ring Gear Assembly
06D-970701 Piston and Pin Assembly
06M6711901 Injector -Fuel
06M6970701 Fuel Rail Asm. 5.7
06N-970701 Body and Switch Assembly -Throttle
06X-121905 Valve -Exhaust
06X-121907 Sprocket -Camshaft
06X-121908 Sprocket -Crankshaft
06X-121909 Chain -Camshaft Drive
06X-121910 Damper -Timing Chain
06X-121911 Bolt -Chain Damper to Cylinder Block
06X-211905 Spring and Damper Assembly -Valve
06X-970301 Camshaft
06Z-970701 Engine Assembly -As Shipped -Auto
06Z-970702 Engine Assembly -As Shipped -Manual
71A-111701 Washer – Header to engine —16 places
72H-381101 Bolt – Header to engine –16 places
06D-711902 Piston and Pin Assembly -0.020" O/S
06D-711903 Piston and Pin Assembly -0.030" O/S
06D-711904 Ring Set -Piston (STD)
06D-711905 Ring Set -Piston -0.020" O/S
06D-711906 Ring Set -Piston -0.030" O/S
06X-121906 Package Chain Drive
06X-711901 Valve -Exhaust -0.008"0/S
3. SENATOR, MANTA AND CLUBSPORT 195i
GENERAL DESCRIPTION
The engine fitted to the Senator, Manta and Clubsport 195i vehicles is a HSV development of the Holden 5 litre
sequential-injection V8 engine. Improvements to the basic engine were designed and tested by HSV, and these
improvements include;
Roller follower high-lift high-duration Cam shaft, timing sprockets and timing chain.
New cylinder heads incorporating larger HSV exhaust springs.
An impr oved Engine Management System - c ustomis ed by HSV - to provide optim um engine per form ance for
all driving conditions.
A new HSV-design Cold Air Intake system, optimised for the new range of VT vehicles.
Two new HSV-design Exhaust Systems providing low restriction and low back-pressure - optimised for use
with the new VT 195i and 220i engines. Both exhaust systems are now fitted with two oxygen sensors.
SERVICE OPERATIONS
The 195i engine fitted to Senator, Manta and Clubsport vehicles is to be serviced as specified in the Holden VT
Series Service Inform ation CD. In addition, ECM/PCMs and MEM-CALS can be identified and serviced by the part
numbers in the following chart
ECM/PCM MEMCAL
DELCO ID HSV SERVICE DELCO ID HSV SERVICE
P/N B/C P/N P/N P/N
195 MANUAL ECM 16268298 CFZC 12F-970301 16268250 12F-970307
195 AUTO PCM 16268288 CFZB 12F-970302 16268246 12F-970304
ENGINE ASSEMBLY – SERVICE
Specific HSV components that have been including in the 195i engine assembly. The part number for these
replacement service components and assemblies are detailed in the table below.
Part Number Description
06A2970301 Head Assembly -Cylinder
06A-211902 Seat -Valve Spring
06X-121905 Valve -Exhaust
06X-121907 Sprocket -Camshaft
06X-121908 Sprocket -Crankshaft
06X-121909 Chain -Camshaft Drive
06X-121910 Damper -Timing Chain
06X-121911 Bolt -Chain Damper to Cylinder Block
06X-211905 Spring and Damper Assembly -Valve
06X-970301 Camshaft
06Z-970301 Engine Assembly -As Shipped -Auto
06Z-970302 Engine Assembly -As Shipped -Manual
71A-111701 Washer – Header to engine —16 places
72H-381101 Bolt – Header to engine –16 places
06D-711902 Piston and Pin Assembly -0.020" O/S
06D-711903 Piston and Pin Assembly -0.030" O/S
06D-711904 Ring Set -Piston (STD)
06D-711905 Ring Set -Piston -0.020" O/S
06D-711906 Ring Set -Piston -0.030" O/S
06X-121906 Package Chain Drive
06X-711901 Valve -Exhaust -0.008"0/S
4. GRANGE 215i
GENERAL DESCRIPTION
The 215i engine package is a HSV designed unit displacing 5718 cubic centimetres. This is an another version of
the 5.7 litre engine. The engine develops 215kW of power at 4800 rpm and a torque of 475Nm at 3600 rpm. The
capacity increase is achieved with a new crankshaft providing a stroke of 88.4mm which, combined with the pre-
existing bore of 101.4 mm, provides a capacity of 5.7 litres. Specific designed pistons are used to give a
compression ratio of 8.55:1. Changes to the camshaft, camshaft drive, cylinder heads, throttle body and engine
micro processor combine to enable the engine package to develop 215kW.
SERVICE OPERATIONS
The Grange 215i is fitted with a specif ic ECM/PCM to contr ol the engine m anagem ent system. T he ECM/PCMs are
fitted with specific Mem-Cals to suit the 215i engine assembly. Both the ECM/PCM's and Mem-Cals can be
identified and serviced by the HSV part numbers in the following chart.
ECM/PCM MEMCAL
DELCO ID HSV SERVICE DELCO ID HSV SERVICE
P/N B/C P/N P/N P/N
215 MANUAL ECM 16211858 BMZN 12F-970701 16211795 12F-970703
215 AUTO PCM 16240008 BWCT 12F-970708 16239970 12F-970709
ENGINE ASSEMBLY – SERVICE
Specific HSV components that have been including in the 215i engine assembly. The part number for these
replacement service components and assemblies are detailed in the table below.
Part Number Description
06A-211901 Head Assembly -Cylinder
06A-211902 Seat -Valve Spring
06A1711901 Block Asm -Engine (5.7L)
06A1711902 Block Complete -Short Motor
06C1711901 Crankshaft 5.7 litres
06C3711901 Fly wheel and Ring Gear Assembly
06D-711901 Piston and Pin Assembly
06M-121901RY Cover Assembly -Fuel Rail RHS (Atlas Grey)
06M-121902RY Cover Assembly -Throttle Body (Atlas Grey)
06M-121906RY Cover Assembly -Fuel Rail LHS (Atlas Grey)
06M-711901 Plate -Engine ID -215
06M6711901 Injector -Fuel
06N-121905 Body and Switch Assembly -Throttle
06X-121904RY Cover Assembly, Valve Rocker LH (Atlas Grey)
06X-121905 Valve -Exhaust
06X-121907 Sprocket -Camshaft
06X-121908 Sprocket -Crankshaft
06X-121909 Chain -Camshaft Drive
06X-121910 Damper -Timing Chain
06X-121911 Bolt -Chain Damper to Cylinder Block
06X-211905 Spring and Damper Assembly -Valve
06X-211907 Camshaft
06X-511901 Cover Assembly Valve Rocker RH (Atlas Grey)
06X1711901 Camshaft and Pin Assembly
06Z-711901 Engine Assembly -As Shipped -Auto
06Z-711902 Engine Assembly -As Shipped -Manual
71A-111701 Washer – Header to engine —16 places
72H-381101 Bolt – Header to engine –16 places
06D-711902 Piston and Pin Assembly -0.020" O/S
06D-711903 Piston and Pin Assembly -0.030" O/S
06D-711904 Ring Set -Piston (STD)
06D-711905 Ring Set -Piston -0.020" O/S
06D-711906 Ring Set -Piston -0.030" O/S
06X-121906 Package Chain Drive
06X-711901 Valve -Exhaust -0.008"0/S
5. GRANGE AND MALOO 185i
GENERAL DESCRIPTION
The Grange and Maloo 185i vehicles are fitted with a simultaneous double-fire fuel-injected Holden V8 engine
assembly. A specific package of HSV designed components are fitted to the engine to enhance engine
performance. This package incorporates a Cold Air Induction system, Low Restriction Exhaust, and an Optimised
Engine Management Systems incorporating a knock sensor. These improvements allow the engine to develop
185kW of power at 4800 rpm and 400Nm of torque at 3600 rpm.
The Cold Air Induction System consists of a HSV designed air cleaner box and a free-flow air duct. The assembly
seals between the radiator support panel and hood. The Air Induction System uses the original Holden airfilter
element. A knock sensor is fitted on the engine and this sensor detects engine detonation under load and varies
ignition timing accordingly.
The Grange and Maloo 185i vehicles are fitted with a specific HSV ECM/PCM to control the engine management
system. The ECM/PCMs are fitted with specific MEM-CALs to suit the 185i engine package.
SERVICE OPERATIONS
The 185i engine package in the Grange and Maloo vehicle is to be serviced as specified in the Holden VS Series
Service Information CD. In addition, ECM/PCMs and MEM-CALS can be identified and serviced by the HSV part
numbers in the following chart.
ECM/PCM MEMCAL
DELCO ID HSV SERVICE DELCO ID HSV SERVICE
P/N B/C P/N P/N P/N
185 MANUAL ECM 16192428 BFPM 12F-651901 16192420 12F-651903
185 AUTO PCM 16239998 BWCS 12F-950114 16239973 12F-950115