Operations Manual - KEM Equipment, Inc.
Contents
1. hanne ELECTRICAL SHOCK HAZARD The ignition system can cause severe shock if proper precautions are not taken ac OVER SPEED PROTECTION The engine is equipped with an over speed protection device to protect against runaway or damage to the engine with possible personal injury loss of life or property damage Diagnostic codes such as over temperature or low oil pressure may cause engine speed reduction WARNING PROPER USE Any unauthorized modifications to or use of this engine outside its specified mechanical electrical or other operating limits may cause personal injury and or property damage including damage to the engine Any such unauthorized modifications i constitute misuse and or negligence within the meaning of the product warranty thereby excluding warranty coverage for any resulting damage and ii invalidate product certifications or listings canon POSSIBLE DAMAGE TO ENGINE OR PROPERTY Auror BATTERY CHARGING To prevent damage to a control system that uses an alternator or battery charging device make sure the charging device is turned off before disconnecting the battery from the system Auror ELECTROSTATIC DISCHARGE Electronic controls contain static sensitive parts Observe the following precautions to prevent damage to these parts Discharge body static before handling the control with power to the control turned off contact a grounded surface and maintain contact while handling2. ECM Throttle Actuator Flame Arrester Serpentine Belt Alternator Tensioner Smooth Idler Pulley Exhaust Manifold Water Purnp Serpentine Belt Individual Coil Packs Grooved Idler Pulley Heat Exchanger Overflow Tank 11 Bussman Fuse Box Post 02 sensor Da e A gt Pre 02 sensor Heat Exchanger Exhaust Riser Fuel Regulator Filter Catalyst Housing Remote Oil filter Exhaust Manifold High Pressure fuel Pump Individual Cylinder Coil Packs Fuel Cooler FuelAWater Separator Engine ID Placard These illustrations show the general location of engine controls and their functions These illustrations will help identify where these parts are located on the engine Locations will vary from engine to engine 12 Parts and Service Replacement parts can be obtained through your local Kodiak engine dealer Kodiak dealers are equipped to perform major and minor repairs They are anxious to see that all of your maintenance and service needs are quickly and courteously completed Please contact KEM Equipment Inc Kodiak Marine regarding any favorable or un favorable experiences with our service dealers The engine model number and serial number will be required when seeking information and or ordering parts There is a list of service dealers located at the very end of this manual Technical support for Kodiak Marine engines can be obtained by contacting KEM Equipment Inc Service Literature By contacting
3. FIXED ORIFICE NAPA 3737 4 BAR 58 PSI AT FUEL RAIL 5W 30 GF 4 ILSAC SPECS 24 6 2L LS3 376 GENERAL ENGINE SPECIFICATIONS Engine 6 2L TYPE V 8 DISPLACEMENT 376 CID VALVE CONFIGURATION OVERHEAD VALVES VALVE LIFTERS HYDRAULIC ROLLER BORE X STROKE INCHES 103 25 X 92MM INTAKE MANIFOLD COMPOSITE FIRING ORDER 1 8 7 2 6 5 4 3 FUEL SYSTEM FUEL INJECTED OIL CAPACITY W REMOTE FILTER 5 5 QTS COOLANT CAPACITY 4 GAL BORE CENTER 111 76 MM FUEL TYPE PREMIUM 91 OR BETTER ENGINE ROTATION CCW FLYWHEEL END QUICK REFERENCE CHART OIL FILTER ORIGINAL LOCATION PF 48 W REMOTE NAPA 21515 FUEL WATER SEPARATOR NAPA 3225 SPARK PLUGS 12621258 SPARK ARRESTER K N 59 5002 SPARK PLUG GAP 062 SERPENTINE BELT 25 060658 FUEL PRESSURE REGULATOR NAPA 3737 FUEL PRESSURE 4 BAR 58 PSI AT FUEL RAIL ENGINE OIL USE ONLY MOBIL 1 5W 30 25 MAINTENANCE SCHEDULE ENGINE CHECK POINTS SERVICE INTERVAL DAILY EVERY 25 HOURS EVERY 50 HOURS EVERY 75 HOURS EVERY 100 HOURS EVERY 150 HOURS EVERY 200 HOURS EVERY 300 HOURS EVERY 400 HOURS Inspect fuel system for leaks GENERAL MAINTENANCE PRIOR TO ANY SERVICE OR MAINTENANCE ACTIVITY Inspect engine for fluid leaks Check engine oil Replace engine oil and filter Inspect accessory drive belts Inspect ECM isolation moun
4. 5 7L 350ci VALVE CONFIGURATION OHV TWO PER CYL VALVE LIFTERS HYD ROLLER BORE X STROKE 4 00 IN X 3 48 IN MAIN BEARING CAPS 2 BOLT BALANCE METHOD EXTERNAL FIRING ORDER 1 8 4 3 6 5 7 2 OIL CAPACITY W O FILTER 6 QTS FUEL TYPE GASOLINE ENGINE ROTATION CCW FLYWHEEL END QUICK REFERENCE CHART OIL FILTER ORIGINAL LOCATION PF 25 W REMOTE NAPA 21515 WATER SEPARATOR FILTER NAPA 3225 SPARK ARRESTOR A7660 SPARK PLUGS 25162556 AC Delco 41 101 SPARK PLUG GAP 062 V BELTS 2 ENGINE OIL NAPA 15435 CV 769 C 4 BAR 58 PSI AT FUEL RAIL 10W 40 GF 4 ILSAC SPECS 23 6 0L 364 GENERAL ENGINE SPECIFICATIONS L96 6 0L 364ci VALVE CONFIGURATION OHV TWO PER CYL VALVE LIFTERS HYD ROLLER BORE X STROKE 101 6 mm x 92 mm MAIN BEARING CAPS 6 BOLT BALANCE METHOD INTERNAL EXTERNAL FIRING ORDER 1 8 7 2 6 5 4 3 OIL CAPACITY W O FILTER 6 QTS FUEL TYPE GASOLINE ENGINE ROTATION CCW FLYWHEEL END QUICK REFERENCE CHART OIL FILTER ORIGINAL LOCATION PF 46 W REMOTE NAPA 21515 WATER SEPARATOR FILTER SPARK ARRESTOR NAPA 3225 KM 10272 SPARK PLUGS 12621258 AC Delco 41 985 SPARK PLUG GAP 062 SERPENTINE BELT PCV VALVE FUEL PRESSURE REGULATOR FILTER FUEL PRESSURE ENGINE OIL NAPA 25 060770
5. BORE X STROKE INCHES 3 44X3 94 MAIN BEARING CAPS 2 BOLT BALANCE METHOD INTERNAL INTAKE MANIFOLD SIDE DRAFT FIRING ORDER 1 3 4 2 OIL CAPACITY W FILTER 4 5 QUARTS FUEL TYPE GASOLINE ENGINE ROTATION CCW FLYWHEEL END QUICK REFERENCE CHART ENGINE 2 4L OIL FILTER ORIGINAL LOCATION PF 47 OR NAPA 1040 WATER SEPARATOR FILTER NAPA 3225 SPARK ARRESTER KM 10272 SPARK PLUGS SPARK PLUG GAP 93206675 OR NGK BPR6ES 040 SERPENTINE BELT NAPA 25 060355 PCV VALVE 25042116 FUEL PRESSURE 3 BAR 43 PSI ENGINE OIL 10W 40 GF 4 ILSAC SPECS 21 GENERAL ENGINE SPECIFICATIONS 4 3L 262 ENGINE 4 3L TYPE V6 DISPLACEMENT 262 CID VALVE CONFIGURATION PUSH ROD VALVE LIFTERS HYDRAULIC ROLLER BORE X STROKE INCHES 4 00 X 3 48 MAIN BEARING CAPS 2 BOLT BALANCE METHOD EXTERNAL FIRING ORDER 1 6 5 4 3 2 OIL CAPACITY W FILTER 4 5 QUARTS FUEL TYPE GASOLINE ENGINE ROTATION CCW FLYWHEEL END QUICK REFERENCE CHART OIL FILTER ORIGINAL LOCATION PF 52 W REMOTE NAPA 21515 WATER SEPARATOR FILTER NAPA 3225 SPARK ARRESTER SPARK PLUGS KM 10272 25162556 OR AC Delco 41 993 SPARK PLUG GAP 062 V BELTS 2 NAPA 15435 PCV VALVE FIXED ORIFICE FUEL PRESSURE 4 BAR 58 PSI AT FUEL RAIL ENGINE OIL 10W 40 GF 4 ILSAC SPECS 22 5 7L 350 GENERAL ENGINE SPECIFICATIONS L 31
6. wait 3 to 4 seconds before re engaging the starter This will prevent possible damage to the starter or the engine Do NOT operate the starter for periods longer than 5 8 seconds at a time An interval of at least 1 minute should be observed between cranking periods to protect the starter from overheating 17 STARTING MODE FUEL INJECTION With the ignition switch in the ON position before engaging the starter the ECM energizes the fuel pump relay for 10 seconds allowing the fuel pump to build pressure The ECM uses the engine coolant temperature ECT the throttle position TPS and the manifold absolute pressure MAP sensors to determine the proper air fuel ratio for starting The ECM controls the amount of fuel delivered in the starting mode by changing the pulse width of the injectors CLEAR FLOOD FUEL INJECTION If the engine becomes flooded clear the engine by opening the throttle to 100 percent When the pedal position sensor PPS is at wide open throttle the ECM reduces the injector pulse width in order to increase the air to fuel ratio The ECM holds this injector rate as long as the throttle stays wide open and the engine speed is below a predetermined RPM If the throttle is not held wide open the ECM returns to the starting mode COLD ENGINE START On a cold engine start the engine idle speed will be elevated until the coolant temperature reaches operating temperature As the engine temperature increases the i
7. 1 Any warranted part that is not scheduled for replacement as required maintenance in the written instructions supplied is warranted for the warranty period stated above If the part fails during the period of warranty coverage the part will be repaired or replaced by KEM Equipment Inc Kodiak Marine according to Subsection 4 below Any such part repaired or replaced under warranty will be warranted for the remainder of the period 2 Any warranted part that is scheduled only for regular inspection in the written instructions supplied is warranted for the warranty period stated above Any such part repaired or replaced under warranty will be warranted for the remaining warranty period 3 Any warranted part that is scheduled for replacement as required maintenance in the written instructions supplied is warranted for the period of time before the first scheduled replacement date for that part If the part fails before the first scheduled replacement the part will be repaired or replaced by KEM Equipment Inc Kodiak Marine according to Subsection 4 below Any such part repaired or replaced under warranty will be warranted for the remainder of the period prior to the first scheduled replacement point for the part 4 Repair or replacement of any warranted part under the warranty provisions herein must be performed at a warranty station at no charge to the owner 5 Notwithstanding the provisions herein warranty services or repairs wi
8. 100 FMI 17 Engine Oil Pressure EOP Sensor Data Valid But Below Normal Range Least Severe Level SPN 105 SPN Descriptors SPN 105 FMI 3 Manifold Air Temperature MAT Sensor Circuit Voltage Above Normal or Shorted High SPN 105 FMI 4 Manifold Air Temperature MAT Sensor Circuit Voltage Below Normal or Shorted Low SPN 106 SPN Descriptors SPN 106 FMI 0 Manifold Absolute Pressure MAP Sensor Circuit Voltage Data Valid But Above Normal SPN 106 FMI 1 Manifold Absolute Pressure MAP Sensor Circuit Voltage Data Valid But Below Normal SPN 106 FMI 3 Manifold Absolute Pressure MAP Sensor Circuit Voltage Above Normal or Shorted High SPN 106 FMI 4 Manifold Absolute Pressure MAP Sensor Circuit Voltage Below Normal or Shorted Low SPN 110 SPN Descriptors SPN 110 FMI 3 Engine Coolant Temperature ECT Sensor Circuit Voltage Above Normal or Shorted High SPN 110 FMI 4 Engine Coolant Temperature ECT Sensor Circuit Voltage Below Normal or Shorted Low SPN 110 FMI 15 Engine Coolant Temperature ECT Sensor Circuit Voltage Data Valid But Above Normal Range Least Severe Level SPN 174 SPN Descriptors SPN 174 FMI 3 Fuel Temperature FT Sensor Circuit Voltage Above Normal or Shorted High SPN 174 FMI 4 Fuel Temperature FT Sensor Circuit Voltage Below Normal or Shorted Low 49 SPN 627 SPN Descriptor SPN 627 FMI 15 System Voltage Data Valid But Above Normal Range Least Severe Level SPN 627 FMI 17 System Voltage Data
9. 6151 Professional Marine 907 562 2471 Cordova Harbor Hydraulics 907 424 3472 North pole Arctic Marine 907 488 5242 Wasilla Marne Valley Diesel and Marine 907 373 2613 Wasilla Arctic Cat 907 376 5845 Arizona Bullhead Holiday RV amp Marine 928 763 2322 California Atascadro Jet Boat Performance 805 466 4719 Bakersfield Custom Boat Works 661 387 1523 Chico All About Boats 530 892 0100 Davis Delta Marine 530 750 5000 Eureka Redwood Marine 707 443 7029 Paradise Wilson Paradise Marine 530 872 2617 Redding Redding Performance Marine 530 246 8889 Dave s Mobile Marine 530 515 5152 Harrison Marine 530 243 0175 Outboard Center 530 241 5430 Shasta Inboards 530 246 2343 Shasta Lake Redding Boat Works 530 275 1495 Yuba City Jet stream Concepts 530 674 0655 Johnson Bait and Marine 530 674 1912 Idaho Boise Whitewater Marine 208 377 5110 Lewiston Riverview Marina Custom Weld 800 859 0356 Michigan Marne Camp amp Cruise 616 677 1274 Montana Billings Jim and Tracy s Alignment 406 259 8496 Butte Rocky Mt RV 406 494 2555 Helena One Way Marine 406 443 7373 Oregon Bend All Season RV amp Marine 541 382 5009 Central Lake Marine 541 385 7791 Central Point Rick s Boat Repair 541 664 8022 Coos Bay Y Marina 541 888 5501 Corvallis Southside Marine 541 753 4241 Eugene Clemens Marine 541 688 5483 Maxxum Marine 541 686 3577 Mel s Marine Service 541 689 0136 Hermiston High Desert Ma
10. Data Erratic Intermittent or Incorrect SPN 65615 65616 or 65618 SPN Descriptors SPN 65615 FMI 7 Electronic Throttle Control ETC Actuation Fault Mechanical System Not Responding or Out of Adjustment SPN 65616 FMI 12 Electronic Throttle Control ETC Process Fault Bad Intelligent Device or Component SPN 65618 FMI 7 Electronic Throttle Control ETC Return Fault Mechanical System Not Responding or Out of Adjustment SPN 65620 or 65621 SPN Descriptors SPN 65620 FMI 4 5 Volt Reference A Circuit Voltage Below Normal or Shorted Low SPN 65621 FMI 4 5 Volt Reference B Circuit Voltage Below Normal or Shorted Low SPN 65675 SPN Descriptor SPN 65675 FMI 11 Catalytic Converter A Efficiency Root Cause Unknown SPN 65723 SPN Descriptors SPN 65723 FMI 2 Camshaft Position CMP Sensor Circuit Data Erratic Intermittent or Incorrect SPN 65723 FMI 7 Camshaft Position CMP Sensor Mechanical System Not Responding or Out of Adjustment SPN 65723 FMI 8 Camshaft Position CMP Sensor Signal Abnormal Frequency or Pulse Width SPN 66001 SPN Descriptor 52 SPN 66001 FMI 3 Starter Relay Low Side Driver Voltage Above Normal or Shorted High SPN 66001 FMI 5 Starter Relay Low Side Driver Current Below Normal or Open Circuit SPN 66003 SPN Descriptor SPN 66003 FMI 3 Malfunction Indicator Lamp MIL Driver Voltage Above Normal or Shorted High SPN 66003 FMI 5 Malfunction Indicator Lamp MIL Driver Current Below Normal or Open Cir
11. OUT OF WATER CHARGES OR TECHNICIAN TRAVEL TIME e GROWTH OF MARINE ORGANISMS ON MOTOR SURFACES EXTERNAL OR INTERNAL DISCLAIMER OF CONSEQUENTIAL DAMAGE AND LIMITATION OF IMPLIES WARRANTIES Kodiak Marine DISCLAIMS ANY RESPONSIBILITY FOR LOSS OF TIME OR USE OF THE INBOARD REVENUE OR THE EQUIPMENT IN WHICH THE INBOARD IS INSTALLED TRANSPORTATION COMMERCIAL LOSS OR ANY OTHER INCIDENTAL OR CONSEQUENTIAL DAMAGE ANY IMPLIED WARRANTIES ARE LIMITED TO THE DURATION OF THIS WRITTEN LIMITED WARRANTY Non Commercial Applications Starters Alternators and Fuel pumps will be warranted for a period of 2 years or 200 hours whichever occurs first Commercial Applications Starters Alternators and Fuel pumps will be warranted for a period of 1 year or 150 hours whichever occurs first Some states do not allow limitations on how long an implied warranty lasts and or do not allow the exclusion or limitation of incidental or consequential damages so the above exclusions and limitations may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary state to state 46 ON BOARD DIAGNOSTIC OBD MEFI CONTROLLED MARINE ENGINE a Fire Shock and Burn Danger When performing any diagnostics or service work use caution This system has extreme fuel pressures and a high voltage ignition Ao Electronic controls contain static sensitive parts Observe the following precautions to prevent dama
12. Valid But Below Normal Range Least Severe Level SPN 630 65580 65581 65582 SPN Descriptors SPN 630 FMI 13 Cal Memory Out of Calibration SPN 65580 FMI 12 CPU Bad Intelligent Device or Component SPN 65581 FMI 12 MHC Failure Bad Intelligent Device or Component SPN 65582 FMI 12 NV RAM Failure Data Erratic Intermittent or Incorrect SPN 636 SPN Descriptors SPN 636 FMI 2 Crankshaft Position CKP Sensor Circuit Data Erratic Intermittent or Incorrect SPN 636 FMI 8 Crankshaft Position CKP Sensor Signal Abnormal Frequency or Pulse Width SPN 651 652 653 or 654 SPN Descriptors SPN 651 FMI 3 Fuel Injector 1 Voltage Above Normal or Shorted High SPN 651 FMI 5 Fuel Injector 1 Current Below Normal or Open Circuit SPN 652 FMI 3 Fuel Injector 2 Voltage Above Normal or Shorted High SPN 652 FMI 5 Fuel Injector 2 Current Below Normal or Open Circuit SPN 653 FMI 3 Fuel Injector 3 Voltage Above Normal or Shorted High SPN 653 FMI 5 Fuel Injector 3 Current Below Normal or Open Circuit SPN 654 FMI 3 Fuel Injector 4 Voltage Above Normal or Shorted High SPN 654 FMI 5 Fuel Injector 4 Current Below Normal or Open Circuit SPN 65541 65542 65543 or 65544 SPN Descriptors SPN 65541 FMI 4 Ignition Coil 1 Voltage Below Normal or Shorted Low SPN 65541 FMI 5 Ignition Coil 1 Current Below Normal or Open Circuit SPN 65542 FMI 4 Ignition Coil 2 Voltage Below Normal or Shorted Low SPN 65542 FMI 5 Ignition Coil 2 Current Below Normal or O
13. and filter 4 Check for oil coolant and fuel leaks Correct any leaks prior to proceeding further 5 Check charge and fluid level of battery Inspect connections for corrosion and clean as necessary 6 Check flame arrestor Make sure that it is cleaned replaced as necessary 7 Inspect the exterior of the heat exchanger clean if necessary 8 Check alternator belt adjust if necessary 9 Remove and replace fuel filter 10 Remove clean adjust test and or replace spark plugs 11 Remove and replace PCV valve if applicable 12 Drain and replace coolant in cooling system 13 Check for loose bolts nuts or any loose pieces 14 Start bilge blower Let blower run for 10 minutes 15 Close engine cover 40 CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT YOUR WARRANTY RIGHTS AND OBLIGATIONS The California Air Resources Board and KEM Equipment Inc Kodiak Marine are pleased to explain the emission control system warranty on your 2011 model year inboard stern drive engine In California new inboard stern drive engines must be designed built and equipped to meet the State s stringent anti smog standards KEM Equipment Inc Kodiak Marine must warrant the emission control system on your inboard stern drive engine for the periods of time listed below provided there has been no abuse neglect or improper maintenance of your inboard stern drive engine Your emission control system includes parts such as the fuel in
14. engine is operating in severe conditions such as dirty areas or during cold weather No oil additives or break in oil are recommended l sunon Do not operate the engine with the oil level below the bottom of the dipstick or Add mark on the dipstick or above the top or Full mark on the dipstick Engine Oil Level Check The engine oil level should be checked daily It is recommended that the oil be checked just before the engine is started for the first time for the day The oil level should be between the ADD and the FULL marks on the dipstick Adding Engine Oil It is normal to add some oil in the period of time between oil changes The amount will vary with the severity of operation When adding or replacing engine oil be sure the oil meets or exceeds the recommended specification Engine Oil Quality To achieve proper engine performance and durability it is important that you use only engine lubricating oils of the correct type in your engine Quality oil also provides maximum efficiency for crankcase ventilation systems which reduces pollution Engine Oil Recommendation Motor oils meeting ILSAC International Lubricant Standardization amp Approval Committee GF 4 standards The GM spec for this oil is 9986231 Motor oils meeting this spec receive the API American Petroleum Institute starburst symbol dexos 27 Oil Filter NOTE Ensure the old filter gasket is removed prior to instal
15. installed in the exhaust stream AL Make sure the raw waterside of heat exchanger is drained when ambient temperature is below 32 Degrees F The following inspections shall be run on your engine at the indicated intervals or more if needed These inspections ensure that your engine will continue to perform at a level it was designed to Make sure that all inspections are performed at their assigned intervals 38 Periodic Maintenance Inspections 100 300 500 700 900 Hour Inspection A WARNING Make sure key is not in ignition and no electrical equipment is energized prior to any engine check or operation Do not energize engine prior to performing the following steps 1 Open engine hatch cover and let compartment air out for ten minutes or more 2 Make sure that no electrical equipment is energized 3 Change engine oil and filter 4 Check coolant level Make sure fluids are at the proper levels 5 Check for oil coolant and fuel leaks Correct any leaks prior to proceeding further 6 Check charge and fluid level of battery Inspect connections for corrosion and clean as necessary 7 Check flame arrestor Make sure that it is cleaned replaced as necessary 8 Inspect the exterior of the heat exchanger clean if necessary 9 Check alternator belt adjust if necessary 10 Check for loose bolts nuts or any loose pieces 11 Start bilge blower Let blower run for 10 minutes 12 Close engine
16. our Parts Department you can purchase parts and service manuals for Kodiak Marine engines 503 692 5012 R The bilge can accumulate explosive fumes The bilge blower will evacuate the fumes The bilge blower must be run for a minimum of 10 minutes prior to cranking the engine A WARNING Do not start or run the engine in a closed or poorly ventilated area where exhaust gases may accumulate All internal combustion engines give off various fumes and gases while running Avoid breathing these gases as they may contain poisonous carbon monoxide and other gases which can endanger your health or life if inhaled steadily for a few minutes CAUTION If the engine stalls or falters during starting wait 3 to 4 seconds before reengaging the starter This will prevent possible damage to the starter or the engine Do NOT operate the starter for periods longer than 5 8 seconds at a time An interval of at least 1 minute should be observed between cranking periods to protect the starter from overheating 13 PRE OPERATIONAL INSPECTION A WARNING Remove the key from the ignition prior to any engine check or operation Do not energize any engine prior to performing any of the following Your KODIAK Marine Engine was inspected and test ran before leaving the factory Before operating a new engine you must follow any pre operational instruction 1 Open the engine hatch cover and let the compartment air out for at least ten minutes 2
17. Always make sure you are working in a well ventilated area when around gasoline 3 Check engine oil level remove dipstick wiping clean and recheck your oil level 4 Inspect the oil and fuel filters for tightness and make sure there are no leaks around these filters 5 Check coolant level refill to the appropriate levels 6 Check for any oil coolant or fuel leaks A CAUTION Follow any leaks and repair any abnormal leakage before continuing 7 Inspect the battery connections for corrosion clean as necessary 8 Check the battery fluid level and state of charge fill as needed 9 Inspect the spark arrester for any obstructions Bugs leaves etc clean or replace as needed 10 Check coolant Hoses for Leaks follow any leaks and repair NOTE It is suggested to use Baking Soda and water to safely clean any corrosion around the Battery connections NOTE If the engine is equipped with a stern or jet drive it must be in neutral prior to starting the engine Starting the engine with the drive engaged imposes unnecessary strain on the battery starter and driven components Inspect the spark arrester for any obstructions bugs leaves etc Clean or replace as needed 14 Check the exterior of the heat exchanger Follow and fix any leaks before continuing 11 Check the alternator belt for any extra play adjust as necessary Does not apply to all engines 12 Tighten all loose nuts and bolts Check for any lo
18. EM Equipment Inc Kodiak Marine Distribution center as soon as a problem exists The warranty repairs will be completed in a reasonable amount of time not to exceed 30 days If satisfactory repairs have not been completed in this amount of time contact KEM Equipment for further instructions If you have any questions regarding your warranty rights and responsibilities you should contact KEM Equipment Inc Kodiak Marine at 503 692 5012 41 GENERAL EMISSIONS WARRANTY COVERAGE KEM Equipment Inc Kodiak Marine warrants to the ultimate purchaser and each subsequent purchaser that this engine is 1 Designed built and equipped so as to conform with all applicable regulations adopted by the Air Resources Board pursuant to its authority in Chapters 1 and 2 Part 5 Division 26 of the Health and Safety Code and 2 Free from defects in materials and workmanship that cause the failure of a warranted part to be identical in all material respects to that part as described in KEM Equipment Inc Kodiak Marine s application for certification The warranty period begins on the date the engine or equipment is delivered to an ultimate purchaser or first placed into service For model year 2011 and later spark ignition inboard and stern drive marine engines a period of 3 years Subject to certain conditions and exclusions as stated below the warranty period on your engine s emission related parts identified below is as follows
19. KODIAK MARINE Marine Operators Manual 2 4L 4 3L 5 7L 6 0L AND 6 2L LS3 ENGINES KEM EQUIPMENT INC 10800 SW HERMAN RD TUALATIN OR 97062 PHONE 503 692 5012 FAX 503 692 1098 KM 10701 REVA IMPORTANT DEFINITIONS A WARNING indicates a potentially hazardous situation that if not avoided could result in death or serious injury A CAUTION indicates a potentially hazardous situation that if not avoided could result in damage to engine or property A NOTE provides other helpful information that does not fall under the warning or caution categories l anune DANGER OF DEATH OR PERSONAL INJURY VO FOLLOW INSTRUCTIONS Read this entire manual and all other publications pertaining to the work to be performed before installing operating or servicing this equipment Failure to follow instructions can cause personal injury and or property damage ANa FOLLOW ALL SAFETY PRECAUTIONS AND REGULATIONS Anyone involved in operation of equipment shall be familiar with the information in the warnings cautions and notes These safety precautions are mandatory and used to augment formal safety U S Coast Guard regulations Anyone operating this equipment should become thoroughly familiar with details of operation of the equipment Such knowledge constantly and properly practiced is the only method for ensuring safety as well as reliable and economical equipment In any boating situation common sense and logic rule the waterways
20. acuate the fumes The bilge blower must be run for a minimum of 10 minutes prior to cranking the engine 36 Auror DO NOT add coolant or water to any engine that has become overheated until the engine cools Adding coolant or water to an extremely hot engine can result in a cracked block or cylinder head The following items may cause the engine to overheat Low coolant level Loose or broken belt Inoperative thermostat Inoperative water pump seawater or circulation or sand trap e Clogged inlet strainer seawater or circulation from jet drive e Clogged heat exchanger tube s Low oil level Ruptured plugged or kinked hoses If you perform the Pre Operational and Operation Procedures as outlined you will find that these items are subsequently checked on a regular basis The habit of performing the Pre Operational and Operational procedures is your best method of ensuring all steps are taken and followed periodically EMISSIONS WARNING PROPER USE Any unauthorized modifications to or use of this engine outside its specified mechanical electrical or other operating limits may cause personal injury and or property damage including damage to the engine Any such unauthorized modifications i constitute misuse and or negligence within the meaning of the product warranty thereby excluding warranty coverage for any resulting damage and ii invalidate product certifications This engine is certified
21. belt must be changed 30 FUEL INJECTION SYSTEM Auror Failure to change the fuel system filter as recommended can result in premature failure of fuel injection system components l Use extreme care when changing the fuel filter Gasoline is highly flammable and under pressure It should not be exposed to open flame sparks or hot engine components Allow the engine to cool to ambient temperature prior to changing fuel filters hanne Fuel is under HIGH pressure Consult equipment service dealer before servicing fuel system ANa The bilge can accumulate explosive fumes The bilge blower will evacuate the fumes The bilge blower must be run for a minimum of 10 minutes prior to cranking the engine Fuel Filter A fuel water separator filter is used in the fuel supply line to the engine This helps prevent contaminates from plugging the fuel injectors The fuel filter is located in the supply line between the fuel tank fuel pump and the engine This filter protects the fuel injectors from debris in the fuel tank This filter must be changed every 500 hours or every 6 months which ever occurs first Fuel Recommendation banne Use extreme care when changing the fuel filter Gasoline is highly flammable and under pressure It should not be exposed to open flame sparks or hot engine components Allow the engine to cool to ambient temperature prior to changing fuel filters 31 hinne The bilge can accumulate explo
22. cause high oil consumption and short engine life A restricted or dirty flame arrestor can cause a low power situation Therefore it is extremely important that the flame arrestor be serviced at the recommended 100 hr intervals or sooner depending on operating conditions 1 Clean screen by washing with solvent 2 Blow dry or allow dripping dry prior to installation 3 Remove all dust and foreign matter from spark arrestor Make sure the flame arrestor is seated properly on the throttle body when reinstalled Do not operate engine without flame arrestor 28 COOLING SYSTEM KEM Equipment and GM Powertrain recommends the use of DEX COOL coolant in all GM engines A 50 50 mixture is recommended anne Never remove the heat exchanger cap under any condition while the engine is operating Failure to follow these instructions could result in damage to the cooling system engine or cause personal injury DO NOT add coolant or water to any engine that has become overheated until the engine cools Adding coolant or water to an extremely hot engine can result in a cracked block or cylinder head AL DO NOT mix DEX COOL pink orange colored with traditional green ethylene glycol Refer to the mixture chart on the container for additional antifreeze protection information DO NOT use alcohol or methanol antifreeze or mix them with the specified coolant Plain water may be used in an emergency except in freezing temperatur
23. cover 400 Hour Inspection l Make sure key is not in the ignition and no electrical equipment is energized prior to any engine check or operation Do not energize engine prior to performing the following steps 1 Open engine hatch cover and let compartment air out for ten minutes or more 2 Make sure that no electrical equipment is energized 3 Change engine oil and filter 4 Check coolant level Make sure fluids are at the proper levels 5 Check for oil coolant and fuel leaks Correct any leaks prior to proceeding further 39 6 Check charge and fluid level of battery Inspect connections for corrosion and clean as necessary 7 Check flame arrestor Make sure that it is cleaned replaced as necessary 8 Inspect the exterior of the heat exchanger clean if necessary 9 Check alternator belt adjust if necessary 10 Remove and replace fuel filter 11 Remove clean adjust test and or replace spark plugs 12 Check for loose bolts nuts or any loose pieces 13 Start bilge blower Let blower run for 10 minutes 14 Close engine cover 800 Hour Inspection WA Make sure key is not in ignition and no electrical equipment is energized prior to any engine check or operation Do not energize engine prior to performing the following steps 1 Open engine hatch cover and let compartment air out for ten minutes or more 2 Make sure that no electrical equipment is energized 3 Change engine oil
24. cuit SPN 66004 SPN Descriptor SPN 66004 FMI 3 Service Vehicle Soon Lamp SVS Voltage Above Normal or Shorted High SPN 66004 FMI 5 Service Vehicle Soon Lamp SVS Current Below Normal or Open Circuit SPN 66013 or 66014 SPN Descriptor SPN 66013 FMI 3 Powertrain Relay Voltage Above Normal or Shorted High SPN 66013 FMI 5 Powertrain Relay Current Below Normal or Open Circuit SPN 66014 FMI 4 Powertrain Relay Contact Voltage Below Normal or Shorted Low SPN 66017 SPN Descriptors SPN 66017 FMI 4 Fuel Pump Relay Voltage Below Normal or Shorted Low SPN 66017 FMI 5 Fuel Pump Relay Current Below Normal or Open Circuit SPN 66018 SPN Descriptor SPN 66018 FMI 3 Tachometer Voltage Above Normal or Shorted High SPN 66018 FMI 5 Tachometer Current Below Normal or Open Circuit SPN 66019 SPN Descriptors SPN 66019 FMI 3 Oxygen Sensor Bank A Sensor 1 Heater Voltage Above Normal or Shorted High SPN 66019 FMI 5 Oxygen Sensor Bank A Sensor 1 Heater Current Below Normal or Open Circuit SPN 66019 FMI 8 Oxygen Sensor Bank A Sensor 1 Heater Abnormal Frequency or Pulse Width SPN 66021 SPN Descriptors SPN 66021 FMI 3 Oxygen Sensor Bank A Sensor 2 Heater Voltage Above Normal or Shorted High SPN 66021 FMI 5 Oxygen Sensor Bank A Sensor 2 Heater Current Below Normal or Open Circuit SPN 66021 FMI 8 Oxygen Sensor Bank A Sensor 2 Heater Abnormal Frequency or Pulse Width 53 UNITED STATES Alaska Anchorage Silver Streak 907 344
25. dd on or modified part Following is a list of those critical emission related parts that are covered under the provisions of this emission warranty 1 Fuel Metering System Fuel injection system Air fuel ratio feedback and control system Intake valve s 2 Air Induction System Intake manifold Air filter 3 Ignition System Spark plugs Electronic ignition system Ignition control module Ignition wires 4 Lubrication System Oil pump and internal parts 5 Positive Crankcase Ventilation PCV System PCV valve Oil filler cap 6 Exhaust System Exhaust Catalyst Oxygen Sensors 43 7 Miscellaneous Items Used in Above Systems Hoses clamps fittings tubing sealing gaskets or devices and mounting hardware Pulleys belts and idlers Vacuum temperature check and time sensitive valves and switches Electronic Controls Exclusions The repair or replacement of any warranted part otherwise eligible for warranty coverage may be excluded from such warranty coverage if KEM Equipment Inc Kodiak Marine demonstrates that the engine has been abused neglected or improperly maintained and that such abuse neglect or improper maintenance was the direct cause of the need for repair or replacement of the part Except as provided in the paragraph above any adjustment of a component that has a factory installed and properly Operating Adjustment limiting device such as an idle limiter cap or plug is eligible for warranty cove
26. de checking to ensure that all connections connectors are fully seated and secured 7 Inspect for aftermarket devices that could affect the operation of the system 8 Search for applicable service bulletins 9 Install a scan tool Verify that the scan tool powers up 10 Ignition ON Engine OFF verify communication with all of the control modules on the vehicle oO oF WP 11 Verify that SPN 65559 is not set if SPN 65559 is set refer to SPN 65559 47 ATTEMPT TO START THE ENGINE Verify that the engine cranks If the engine does not crank refer to SPN 66001 or SPN 66002 if equipped If the engine is not equipped with an ECM controlled starter relay repair the starting system Attempt to start the engine Verify the engine starts and idles Important Do not clear any SPNs unless instructed to do so by a diagnostic procedure Use the appropriate scan tool selections to obtain SPNs from each of the vehicle modules Verify there are no SPNs reported from any module If any SPNs are present diagnose any current SPNs in the following order Any of the following 630 65580 65581 or 65582 SPN 627 Component level SPNs System level SPNs Any remaining SPNs 48 DIAGNOSTIC ERROR CODES SPN 100 SPN Descriptors SPN 100 FMI 3 Engine Oil Pressure EOP Sensor Circuit Voltage Above Normal or Shorted High SPN 100 FMI 4 Engine Oil Pressure EOP Sensor Circuit Voltage Below Normal or Shorted Low SPN
27. dle speed will gradually decrease this is a normal engine control function 18 STOPPING THE ENGINE NORMAL CONDITIONS Let the engine idle for at least one minute prior to stopping the engine to reduce residual heat in engine components Not doing this will not harm anything but gives the engine a chance to reduce the temperature of many components STOPPING THE ENGINE UNDER ABNORMAL CONDITIONS Overheating 1 Put engine in NEUTRAL 2 Place gearshift or bucket control lever in Neutral 3 Turn key to the OFF position and remove the key from the ignition 4 If the engine is overheating due to loss of coolant it is best to stop the engine immediately 5 Check and adjust the oil and coolant levels 6 Once the engine has cooled considerably add your coolant slowly until the heat exchanger is full hanne Allow the engine to cool at least a few minutes before attempting to remove the heat exchanger cap Cover the cap with a thick cloth and slowly turn counterclockwise allowing the pressure to release SLOWLY When pressure has been completely released push down on the cap turn and remove A CAUTION Do not add coolant until the engine has returned to normal temperature When you can place your hand on the engine without burning is usually a good indication 19 MAINTENANCE INSTRUCTIONS Auror Neglecting proper maintenance can cause premature component failures Initial Start Up Maintenance The initial sta
28. e Will Crank Intermittently When the Engine Makes a Stuttering or Chattering Noise Engine Cranks But Does Not Start Engine Runs Hot Clear Flood Mode Emissions Storage Page 38 Short Term Lay up Long Term Lay up Periodic Maintenance Inspections Page 39 40 100 400 800 900 Hour Inspections Warranty Page 41 46 On Board Diagnostic OBD System Check Page 47 48 Diagnostic Codes Page 49 53 Service Dealer Locations Page 54 55 United States Canada Russia Wiring Diagrams Page 56 60 INTRODUCTION KEM Equipment Inc is pleased that you have selected a Kodiak engine for your requirements KEM Equipment Inc takes great pride in our tradition of quality products produced from the GM Powertrain line of marine gasoline fuel engines KEM Equipment Inc engines are inspected and tested before leaving the factory However certain checks should be made before placing the engine into regular service Please read the initial start up inspection requirements in the Maintenance section of this manual This Marine Operators Manual covers the 2 4L 4 3L 5 7L 6 0L AND THE 6 2L LS3 Marine Engines In this manual we have included tables for General Engine Specifications and tables for General Maintenance Using this Manual will help you get acquainted with your engine and its functions as well as help with routine service and maintenance to keep your Kodiak Marine Engine performing to its f
29. e blower must be ran for a minimum of 10 minutes prior to cranking the engine Type of Ignition System The ignition on Kodiak engines are controlled by an ECM some use a distributor and some are distributorless Turning or moving the distributor on engines so equipped will not change the ignition timing If the distributor is adjusted it can cause cross firing between cylinders Auror Always use the recommended spark plugs for your engine Hotter or colder plugs or similar plugs that are not exact equivalents to the recommended plugs can cause permanent engine damage or reduce the engines useful life and cause many other problems such as hard starting spark knock and run on Premature failure of catalyst and exhaust emissions may occur Spark plugs should be replaced at the recommended intervals as described in the Maintenance Schedule on page 26 Use only the recommended spark plugs or an equivalent as described in the General Specifications Spark plug gap should be adjusted as recommended in the General Specifications Use the quick reference guide for your individual engine starting on page 20 of this manual 33 TROUBLESHOOTING hanne The bilge can accumulate explosive fumes The bilge blower will evacuate the fumes The bilge blower must be run for a minimum of 10 minutes prior to cranking the engine NOTE A Malfunction Indicator Light must be installed with this engine to be compliant with EPA and CARB regu
30. e problem However if you should require further assistance write or call Kodiak Marine Kodiak Marine 10800 SW Herman Rd Tualatin OR 97062 503 692 5012 45 EXCLUSIONS THIS WARRANTY DOES NOT EXTEND TO THE FOLLOWING e CONDITIONS CAUSED BY LACK OF ROUTINE MAINTENANCE AS OUTLINED IN THE OPERATOR S MANUAL e CONDITIONS CAUSED BY THE USE OF AN IMPELLER OR IMPELLERS THAT DO NOT ALLOW THE INBOARD ENGINE TO RUN IN ITS RECOMMENDED FULL THROTTLE RPM RANGE ALL ELECTRICAL COMPONENTS FOR THE THIRD 3 YEAR LABOR AND FREIGHT FOR THE THIRD 3 YEAR OPERATION INCONSISTENT WITH THE RECOMMENDED OPERATION DUTY CYCLE AS OUTLINED IN THE OPERATOR S MANUAL PARTS AFFECTED OR DAMAGED BY AN ACCIDENT AND OR COLLISION e NORMAL WEAR AND TEAR FUEL CONTAMINATION AND WATER ENTERING ENGINE THROUGH THE FUEL INTAKE AIR INTAKE OR EXHAUST SYSTEM OPERATION WITH FUELS OILS ADDITIVES AND LUBRICANTS WHICH ARE NOT SUITABLE FOR USE IN THE PRODUCT USE IN AN APPLICATION FOR WHICH THE INBOARD ENGINE WAS NOT DESIGNED SUCH AS RACING OR COMPETITIVE USE OR ANY OTHER MISUSE OR NEGLECT INCORPORATION OF UNSUITABLE ATTACHMENTS OR PARTS THE UNAUTHORIZED ALTERATION IMPROPER INSTALLATION AND OR RIGGING OR ANY CAUSES OTHER THAN DEFECTS IN MATERIAL OR WORKMANSHIP CORROSION TO ELECTRICAL COMPONENTS CORROSION DUE TO ELECTROLYSIS WATER BORN FOREIGN CHEMICALS IMPROPER SERVICE OR CORROSION CAUSED BY DAMAGE OR ABUSE REIMBURSEMENT FOR TOWING CHARGES IN AND
31. e to carbon monoxide gases It is important that regular inspections of the exhaust system and the engine s fresh air vents are clean and free of obstructions Check that all maintenance is properly performed by a qualified technician Adequate air ventilation in all areas of your boat is necessary in order to prevent build up of carbon monoxide gas Table of Contents Introduction Page 8 9 Safety Summary How to use this manual Engine Identification Page 10 13 Engine ID Warranty Card Component ID Pre Operational Inspection Page 14 16 Engine fluid levels Belts Battery connections Hoses Flame Arrestor Malfunction Indicator Light MIL Starting the Engine Page 17 18 Starting Mode Fuel injection Clear Flood Cold Start Stopping the Engine Page 19 Normal Conditions Abnormal conditions overheating Maintenance Instructions Page 20 26 General Engine Specifications Quick Reference Guide Maintenance Schedule Changing Engine Oil and Filter Page 27 28 Engine Oil Quality Engine Oil recommendations Oil Filter Engine Flame Arrestor Page 28 Clean or Replace Flame Arrester Cooling System Page 29 30 Heat Exchanger Coolant Level Serpentine Belt Fuel Injection System Page 31 32 Fuel Filter Fuel Recommendation Fuel Type Fuel Quality Changes Power Loss at Higher Elevations Ignition System Page 33 Troubleshooting Page 34 37 Engine Does Not Crank Engin
32. es but replace it with the specified coolant as quickly as possible to avoid damage to the system COOLANT LEVEL Check the coolant level of the heat exchanger daily and only when the engine is cool Generally a good time to do this is just prior to starting the engine for the first time each day Plain water may be used in an emergency and above 32 F ambient temperature but replace it with the specified coolant as quickly as possible to avoid freezing or damage to the cooling system 29 Heat Exchanger Check the coolant level in the heat exchanger daily prior to operation Make sure the coolant level is within to 1 2 inches below the filler neck seat Check the condition of the rubber seal on the coolant filler cap Make sure the rubber seal is clean and free of any dirt particles Make sure the filler neck is clean then replace cap Check all hoses and connections for leaks Check coolant overflow tank level fill to cold line prior to operation Check all hoses for cracks frayed points or spongy areas replace as necessary O O G N Serpentine Belt Most Kodiak engines utilize serpentine belts on the front of the engine others use V belts This type of belt system incorporates a belt tensioning device that keeps the belt at the proper tension This belt should be checked routinely for cracks or checking on the groove side of the belt If cracks or checking are apparent the
33. essel manufacturers are using CAN BUS displays that can retrieve the error codes but cannot clear them See the vessel manufacturers instructions to retrieve the error codes with their device 16 STARTING THE ENGINE Prior to starting the engine the following must be performed 1 Check engine oil level 2 Check for fuel leaks 3 Run bilge blower for a minimum of 10 minutes 4 Check Coolant level 5 Check bilge for excess water before starting engine Aisne The bilge can accumulate explosive fumes The bilge blower will evacuate the fumes The bilge blower must be run for a minimum of 10 minutes prior to cranking the engine hanne Do not start or run the engine in a closed or poorly ventilated area where exhaust gases may accumulate All internal combustion engines give off various fumes and gases while running Avoid breathing these gases as they may contain poisonous carbon monoxide and other gases which can endanger your health or life if inhaled steadily for a few minutes Auror The bilge should be checked for excess water prior to starting the engine Excess water can cause premature starter failure and damage to other engine components NOTE This engine is equipped with a computer controlled starter circuit It is not necessary to hold the ignition switch in start mode until the engine starts although holding the key on will not cause any issues lauron If the engine stalls or falters during starting
34. for inboard use only in jet drive and stern drive vessels Installation of this engine in outboard applications is a violation of the Clean Air Act This engine and its systems are designed to meet CARB and EPA emissions requirements 37 STORAGE Lay Up ONE MONTH 1 Check coolant protection and fluid levels 2 Add proper amount of marine formula Stabil fuel additive or equivalent to the fuel tank 3 Start the engine 4 Treating the engine with a fogger is not recommended as this will damage the catalytic converters installed in the exhaust stream 5 Shut off ignition switch 6 Disconnect battery 7 Leave spark plugs in holes or seal with suitable threaded plugs 8 Cover all openings into the engine with dust proof cap or shields Make sure the raw water side of heat exchanger is drained when ambient temperature is or may go below 32 F 0 C STORAGE Lay Up FOR INDEFINITE PERIOD 1 Add proper amount of marine formula Stabil fuel additive or equivalent to the fuel tank 2 Drain oil from crankcase refill with recommended engine oil SAE 10W40 or equivalent 3 Shut off ignition switch 4 Check coolant protection and fluid levels 5 Disconnect and remove battery 6 Leave spark plugs in holes or seal with suitable threaded plugs 7 Cover all openings into the engine with dust proof cap or shields 8 Treating the engine with a fogger is not recommended as this will damage the catalytic converters
35. ge to these parts Discharge body static before handling the control Make sure power to the control is turned off contact a grounded surface and maintain contact while handling the control Avoid all plastic vinyl and Styrofoam except antistatic versions around printed circuit boards Do not touch the components or conductors on a printed circuit board with your hands or with conductive devices 1 Verify that none of the following preliminary inspections tests reveal the cause of the vehicle concern before beginning diagnosis e Ensure that the battery is fully charged e Ensure that the battery cables are clean and tight Inspect for any open fuses e Ensure that the grounds are clean tight and in the correct location Inspect the easily accessible systems or the visible system components for obvious damage or conditions that could cause the concern This would include checking to ensure that all connections connectors are fully seated and secured Inspect for aftermarket devices that could affect the operation of the system e Search for applicable service bulletins Ensure that the battery is fully charged Ensure that the battery cables are clean and tight Inspect for any open fuses Ensure that the grounds are clean tight and in the correct location Inspect the easily accessible systems or the visible system components for obvious damage or conditions that could cause the concern This would inclu
36. ifold Air Pressure MAP sensor NOTE If the Check Engine light is illuminated it will remain on until the problem is corrected and the engine has gone through three consecutive warm up cycles or if the light has been cleared by a service technician with a scan tool A warm up cycle is a starting temperature close to ambient increasing to operating temperature 15 The second indicator is the Check Gauges light This bulb will illuminate when a non emissions related issue occurs Items that can cause these codes are high or low oil pressure and coolant temperature and various power relay operation system voltage etc The lighting of this fault indicator would indicate to the operator that the gauges for oil pressure and coolant temperature should be checked immediately and action taken to eliminate engine damage There are safeties in the calibration that will reduce engine speed if the sensor output is out of the normal range low oil pressure when the engine is at rated speed for instance If the engine should turn off for no apparent reason check this lamp This light will clear on it s own if the fault clears and the ignition switch is turned off then back on If this light turns off on it s own the issue will stay in memory for 40 warm up cycles or until a technician clears it manually with a scan tool NOTE The lamps will not flash the error codes To retrieve and reset the error codes a diagnostic scan tool is required Some v
37. jection system the ignition system and catalytic converter Also included may be hoses belts connectors and other emission related assemblies Where a warrantable condition exists KEM Equipment Inc Kodiak Marine will repair your inboard stern drive engine at no cost to you including diagnosis parts and labor KEM EQUIPMENT INC KODIAK MARINE WARRANTY COVERAGE Select emission control parts from model year 2011 and later inboard or stern drive engines are warranted for 3 years If any emission related part on your engine is defective under warranty the part will be repaired or replaced by KEM Equipment Inc Kodiak Marine OWNER S WARRANTY RESPONSIBILITIES As the inboard stern drive engine owner you are responsible for the performance of the required maintenance listed in your owner s manual KEM Equipment Inc Kodiak Marine recommends that you retain all receipts covering maintenance on your inboard stern drive engine but KEM Equipment Inc Kodiak Marine cannot deny warranty solely for the lack of receipts or your failure to ensure the performance of all scheduled maintenance As the inboard stern drive engine owner you should however be aware that KEM Equipment Inc Kodiak Marine may deny you warranty coverage if your inboard stern drive engine or a part has failed due to abuse neglect improper maintenance or unapproved modifications You are responsible for presenting your inboard stern drive engine to a K
38. lations Proper connections will be covered in the wiring section of this manual The largest percentage of all malfunctioning equipment will be due to simple or small problems Most operating troubles that might be encountered with a new or well maintained unit will be of a minor nature Consequently if you experience any problems starting or operating your engine look for a simple cause rather than failure of a major component The following list should cover the most common problems Loose or corroded battery connections are more common than battery failure Loose ignition wire connection more common than distributor coil or ignition e Severe weather conditions temps below 32 F 0 C can cause condensation on the inside of the engine e Operating conditions load changes e Change of periodic servicing e Change of grade or purity of fuel Contaminated fuel will often foul engine components e Change of operator Engine troubles that develop as a result of normal use and wear usually give plenty of advance notice warning These problems usually develop as a result of neglected periodic maintenance Whenever engine performance appears less than normal in any area you should consult with your KODIAK dealer immediately Do not wait for a problem to develop Careful attention to periodic regular maintenance will prevent most problems Refer to the periodic maintenance section for checklists 34 Engine Does Not C
39. ling the new filter The Kodiak GM Powertrain engines use an AC Delco or equivalent oil filter as original equipment An equivalent oil filter must be used when servicing the engine see Engine Specifications starting on page 20 for the recommended oil filter for your engine The filter protects your engine from harmful abrasive or sludgy particles without blocking the flow of oil to vital engine parts To replace the filter use a proper filter wrench to remove the filter Clean the filter mounting base and lightly coat the gasket surface of the new filter with engine oil Hand tighten the filter until the gasket contacts the base then tighten another 12 turn Fill the engine with the correct amount of oil run the engine and check for oil leaks at the drain plug and filter gasket Tighten as necessary to stop any oil leakage FLAME ARRESTER The purpose of the flame arrestor is to contain any possible flame that gets into the intake manifold due to an engine failure but also serves other purposes lauron Service the flame arrestor more frequently under severely dusty or dirty conditions Your flame arrestor does not filter the air entering the engine induction system but does act as a silencer The flame arrester is not an actual air filter Air that contains dirt and grit produces an abrasive fuel mixture and can causes severe damage to the cylinder walls and piston rings Damage to the cylinder walls and piston rings will
40. ll be provided at all KEM Equipment Inc Kodiak Marine distribution centers that are franchised to service the subject engines 42 6 The engine owner will not be charged for diagnostic labor that is directly associated with diagnosis of a defective emission related warranted part provided that such diagnostic work is performed at a warranty station 7 KEM Equipment Inc Kodiak Marine is liable for damages to other engine components proximately caused by a failure under warranty of any warranted part 8 Throughout the engine s warranty period defined above KEM Equipment Inc Kodiak Marine will maintain a supply of warranted parts sufficient to meet the expected demand for such parts 9 Any replacement part may be used in the performance of any warranty maintenance or repairs and must be provided without charge to the owner Such use will not reduce the warranty obligations of KEM Equipment Inc Kodiak Marine 10 Add on or modified parts as defined in Section 1900 b 1 and b 10 Title 13 that are not exempted by the Air Resources Board may not be used The use of any non exempted add on or modified parts by the ultimate purchaser will be grounds for disallowing a warranty claim made in accordance with these warranty procedures and Policies KEM Equipment Inc Kodiak Marine will not be liable under these warranty procedures and policies to warrant failures of warranted parts caused by the use of a non exempted a
41. low Normal SPN 65567 SPN Descriptors SPN 65567 FMI 8 Oxygen Sensor Bank 1 Sensor 1 Abnormal Frequency or Pulse Width SPN 65567 FMI 10 Oxygen Sensor Bank 1 Sensor 1 Abnormal Rate of Change SPN 65590 65591 65592 65593 or 65594 SPN Descriptors SPN 65590 FMI 7 Misfire Mechanical System Not Responding or Out of Adjustment SPN 65591 FMI 7 Misfire Cylinder 1 Mechanical System Not Responding or Out of Adjustment SPN 65592 FMI 7 Misfire Cylinder 2 Mechanical System Not Responding or Out of Adjustment SPN 65593 FMI 7 Misfire Cylinder 3 Mechanical System Not Responding or Out of Adjustment SPN 65594 FMI 7 Misfire Cylinder 4 Mechanical System Not Responding or Out of Adjustment SPN 65601 65602 or 65610 SPN Descriptors 51 SPN 65601 FMI 2 Throttle Position TP Sensor 2 Data Erratic Intermittent or Incorrect SPN 65602 FMI 2 Throttle Position TP Sensor 1 Data Erratic Intermittent or Incorrect SPN 65610 FMI 2 Throttle Position TP Sensor 1 and 2 Data Erratic Intermittent or Incorrect SPN 65604 65605 or 65613 SPN Descriptors SPN 65604 FMI 2 Pedal Position PP Sensor 2 Data Erratic Intermittent or Incorrect SPN 65604 FMI 12 Pedal Position PP Sensor 2 Bad Intelligent Device or Component SPN 65605 FMI 2 Pedal Position PP Sensor 1 Data Erratic Intermittent or Incorrect SPN 65605 FMI 12 Pedal Position PP Sensor 1 Bad Intelligent Device or Component SPN 65613 FMI 2 Pedal Position PP Sensor 1 and 2
42. o CALIFORNIA EMMISSIONS REGULATIONS FOR sPARK Ifs uk D REFER TO THE OWNER S MANUAL FOR MAINTENANCE SPECIFICATION AND ADJUSTMENTS This manual covers the 2 4L 4 3L 5 7L 6 0L and the 6 2L LS3 Marine Engines Fill in the information from your engine in the above representation of the engine tag for future reference MODEL This is the part number for the engine and this number should be recorded for ease of obtaining information or parts for this engine SERIAL NUMBER This number identifies each individual engine This number should also be recorded for the ease of obtaining information for this engine If you have a request or need to order service parts this serial number will be requested to aid our parts dept in fulfilling your order The serial number will confirm that you are ordering the correct parts for your engine WARRANTY CARD The warranty card shipped with your engine must be filled out and returned to KEM within 30 days of receipt of your new vessel This warranty card will also need to be filled out and returned if a re power is being performed with a new Kodiak engine Failure to fill out and return your warranty card to KEM within this time period can void all warranties related to this engine This warranty card also helps to identify your engine and its related parts Component Identification Heat Exchanger Bussman Fuse Box Map Sensor i Post 02 sensor Catalyst Housing Pre 02 sensor
43. ose pieces and tighten as necessary 13 Start and run the bilge blower for at least 10 minutes 14 Replace the engine cover A CAUTION All water must be drained from the raw water side of the heat exchanger when surrounding environment temperature is below 32 F 0 C MALFUNCTION INDICATOR LIGHT A caution Notice To Builder Installer This engine requires use of a MIL A MIL Malfunction Indicator Lamp must be installed with this engine to be in compliance with EPA and CARB regulations There are two lights on the dash to indicate engine related problems The operator is responsible to scan for illuminated bulbs during the course of engine operation The first indicator is the Check Engine Light The MIL conveys to the operator that a fault exists that is related to the engine s control system When this light is illuminated a fault code has been set that requires immediate attention or engine component damage could conceivably occur Please stop operation of engine as soon as safely possible Request that a technician inspect the fault code setting He or she will connect a scan tool to determine the cause of the MIL illuminating repair the problem and clear the codes The MIL related codes are caused by sensor output and or conditions that adversely affect the operational output of the engine Some of the components that can cause problems are crank sensor cam sensor fuel injectors regulators ignition system and Man
44. pen Circuit SPN 65543 FMI 4 Ignition Coil 3 Voltage Below Normal or Shorted Low SPN 65543 FMI 5 Ignition Coil 3 Current Below Normal or Open Circuit SPN 65544 FMI 4 Ignition Coil 4 Voltage Below Normal or Shorted Low SPN 65544 FMI 5 Ignition Coil 4 Current Below Normal or Open Circuit SPN 65559 SPN Descriptors SPN 65559 FMI 11 CAN Bus Hardware Fault Root Cause Unknown 50 SPN 65560 SPN Descriptors SPN 65560 FMI 9 CAN Bus Governor Command Abnormal Update Rate SPN 65561 65562 SPN Descriptors SPN 65561 FMI 0 Oxygen Sensor Bank A Sensor 1 Data Valid But Above Normal SPN 65561 FMI 1 Oxygen Sensor Bank A Sensor 1 Data Valid But Below Normal SPN 65561 FMI 3 Oxygen Sensor Bank A Sensor 1 Voltage Above Normal or Shorted High SPN 65561 FMI 4 Oxygen Sensor Bank A Sensor 1 Voltage Below Normal or Shorted Low SPN 65561 FMI 5 Oxygen Sensor Bank A Sensor 1 Current Below Normal or Open Circuit SPN 65562 FMI 0 Oxygen Sensor Bank A Sensor 2 Data Valid But Above Normal SPN 65562 FMI 1 Oxygen Sensor Bank A Sensor 2 Data Valid But Below Normal SPN 65562 FMI 3 Oxygen Sensor Bank A Sensor 2 Voltage Above Normal or Shorted High SPN 65562 FMI 4 Oxygen Sensor Bank A Sensor 2 Voltage Below Normal or Shorted Low SPN 65562 FMI 5 Oxygen Sensor Bank A Sensor 2 Current Below Normal or Open Circuit SPN 65565 SPN Descriptors SPN 65565 FMI 0 Fuel Trim Bank 1 Data Valid But Above Normal SPN 65565 FMI 1 Fuel Trim Bank 1 Data Valid But Be
45. rage under General Emissions Warranty Coverage above Non Commercial Applications Starters Alternators and Fuel pumps will be warranted for a period of 2 years or 200 hours whichever occurs first Commercial Applications Starters Alternators and Fuel pumps will be warranted for a period of 1 year or 150 hours whichever occurs first 44 KODIAK MARINE ENGINE WARRANTY 3 YEAR LIMITED WARRANTY EFFECTIVE JANUARY 1 2011 Products Covered Length of Warranty from date of original retail purchase Non commercial Commercial Rental Non rental Inboard Engines 2011 and 36 months 480 hours 12 months 480 hours newer The Kodiak Marine Inboard Engine must be purchased from an authorized Kodiak Marine dealer This limited warranty applies to the first retail purchaser and each subsequent owner during the applicable warranty time period Kodiak Marine will repair or replace at its option any part that is proven to be defective in material or workmanship under normal use during the applicable warranty time period Warranty repairs and replacements will be made without charge for parts or labor Anything replaced under warranty becomes property of Kodiak Marine All parts replaced under warranty will be considered as part of the original product and any warranty on those parts will expire coincidentally with the original product warranty The warranty shall commence after receipt of a properly completed Warranty Regi
46. rank hanne Make sure there are no fuel leaks before going any further Clean up any spills and always work in a well ventilated area ARNING To avoid any electrical injuries always replace any broken wires before proceeding anne The bilge can accumulate explosive fumes The bilge blower will evacuate the fumes The bilge blower must be run for a minimum of 10 minutes prior to cranking the engine e Check battery cables adjust any loose connections and clean any corrosion e Check battery charge e Check electrical leads something may be loose or disconnected e Check all fuses and relays e Refer to Pre Operational checklist for further checks Engine Will Crank Intermittently Having to turn the key to START several times e Check the ignition switch for loose corroded disconnected or broken wires Tighten or replace as necessary When The Engine Makes A Stuttering Or Chattering Noise e Check the battery cables for loose connections e Check battery charge charge if necessary e Check the starter motor and solenoid switch for loose or disconnected wires e Check ground connections for loose corroded disconnected or broken wires If all electrical connections have been checked for loose connections corrosion broken wires and disconnected wires and after you have reviewed and performed the Operational Instructions contact your service dealer Engine Cranks But Does Not Start Failure
47. rine 541 567 8419 Gold Beach Precision Performance 541 247 2232 Klamath Falls American Marine 541 884 6858 Medford River Marine Sales and Service 503 779 6161 Performance Marine 541 944 7060 54 Oregon continued Mulino Squeeky s Marine 503 632 3257 Oregon City Oregon City Marine 503 656 4276 Portland Advanced Marine 503 762 2294 Pacific Power Boats 503 288 9350 Sigler Marine 503 252 5431 Salem Dennis Boat Shop 503 363 2898 South Beach Newport Marine and RV 541 867 3704 Tigard Steven s Marine 503 620 7023 Washington Chinook Chinook Marine Repair 360 777 8361 Longview Columbia Marine Services 360 430 1010 Seattle Coastal Marine Engine 206 784 3703 Tacoma Harbor Services 888 627 3066 Washougal Riverside Marina 360 835 8553 Woodinville Doug s Boats 800 215 3684 3 Rivers Marine 425 415 1575 Canada British Columbia Chilliwack BC Cascade Supply amp Marine 800 663 2269 Ventures River Boats 604 824 1498 Richmond BC California Marine 604 278 1880 Alberta Red Deer AB Outlaw Marine 403 347 4565 Sylvan Lake AB Eagle Marine LTD 403 887 2430 Russia Krasnoyarsk Rosomaha Boats 7 902 940 12 07 Ka Hem Boats 7 902 940 6498 660054 Russia Krasnoyarsk Laletino 7 5 55
48. rt up checks must be made before entering the engine into service Please refer to the Maintenance Schedule on page 26 and perform the initial start up operations in the sequence shown in column 1 Routine Maintenance Routine maintenance provides the best solution for making sure that the engine is ready when you are The following are some routine service points e Keep the fuel tank filled A full tank of fuel reduces the possibility of condensation forming in the fuel tank and moisture entering the fuel system e Make frequent checks for engine oil fuel and coolant leaks Repair any oil fuel or coolant leaks e Check battery condition and cables frequently clean as necessary e Keep the engine air filter and or spark arrestor clean e Monitor engine coolant temperature e Monitor engine oil pressure and fuel pressure e Check voltmeter and charging system Lubricate Drive Shaft universal joints as described in scheduled preventive maintenance section Some applications Knowing normal gauge values will help you determine abnormal conditions Maintenance Schedule Refer to the Maintenance Schedule on page 26 to ensure that all of the maintenance items listed are checked and replaced at the recommended hours 20 2 4L 147 ENGINE GENERAL ENGINE SPECIFICATIONS 2 4L TYPE L4 DISPLACEMENT 2405cc 147 CID VALVE CONFIGURATION SINGLE O H CAM VALVE LIFTERS HYDRAULIC FOLLOWER
49. sive fumes The bilge blower will evacuate the fumes The bilge blower must be run for a minimum of 10 minutes prior to cranking the engine Fuel Type 2 4L 4 3L 5 7L 6 0L ENGINES Unleaded 87 Octane or better fuel is recommended Lower octane fuels will reduce overall engine performance Maximum Ethanol content is 10 6 2L LS3 ENGINE PREMIUM 91 MINIMUM OCTANE RECOMMENDED Fuel Quality Changes Power Loss At Higher Elevations Fuel injected engines will lose 3 5 power for every 1000 feet the engine is operated above sea level All fuel injection systems installed by KEM Equipment Inc are equipped with a manifold absolute pressure sensor MAP Sensor The MAP sensor senses barometric pressure and automatically corrects the fuel system calibration for changes in altitude This means the air fuel mixture will always be optimized regardless of elevation or barometric pressure however the engine will still lose 3 5 power for every 1000 ft increase in elevation All engines will experience power loss when operated at elevations above sea level unless they are turbocharged or supercharged Turbochargers and superchargers are mechanical pumps that put extra air into the engine to make up for the lower air density at higher elevations 32 IGNITION SYSTEM hanne High voltage ignition system Electrical shock hazard anne The bilge can accumulate explosive fumes The bilge blower will evacuate the fumes The bilg
50. stration at the factory on the date of the first retail purchase and extends to original and subsequent purchasers However in no event shall the duration of this warranty exceed three 3 years or 480 hours whichever occurs first measured from the original retail sale date All subsequent purchasers must inform Kodiak in writing and with a payment of 100 00 transfer fee to continue the warranty If Kodiak does not receive notification and payment within 15 days of the resale the warranty will be null and void Third year 3 of the warranty period is limited to defects in the materials and workmanship only You must have your dealer verify hours before the start of the warranty claim and a no exception 150 00 deductible will apply to each warranty claim during the third year of the warranty period Warranty service must be requested by calling Kodiak Marine to be directed to your closest authorized service center to deliver the product for inspection A properly completed warranty registration must be on file with KEM You must take your Kodiak Marine Inboard Engine and proof of the original purchase date at your expense to any a designated authorized Kodiak Marine service facility during the dealers normal business hours If you are unable to obtain warranty service or are dissatisfied with the warranty service you receive take the following steps First contact the manager or owner of the dealership involved normally this should resolve th
51. the control Avoid all plastic vinyl and Styrofoam except antistatic versions around printed circuit boards Do not touch the components or conductors on a printed circuit board with your hands or with conductive devices AN CAUTION WELDING When welding on the vessel disconnect the battery switch along with the connectors for the Engine Control Module ECM If left connected there is a chance of damage to the ECM R BATTERY GROUNDING Do not connect battery ground or any accessory ground wires to the starter mounting bolts Doing so can cause a loose bolt situation over time that will cause starter failure or a possible damaged engine block NA CARBON MONOXIDE EXPOSURE Carbon Monoxide is an odorless colorless and tasteless gas that cannot be smelled seen or tasted Over exposure to carbon monoxide gas may lead to brain damage unconsciousness or even death Carbon Monoxide is a hazardous gas that is produced when items containing carbon are burned Items such as wood charcoal gasoline natural gas propane and petroleum products such as oil Carbon Monoxide is found in many areas and is produced by all types of internal combustion engines heaters charcoal grills and any other open flame appliances There are many possible situations for the accumulation of carbon monoxide to occur in your vessel Wind direction boat speed and being close to other vessels are just a few of the possible ways that would permit exposur
52. to change the fuel system filter as recommended can result in premature failure of fuel injection system components 35 hinne Use extreme care when changing the fuel filter Gasoline is highly flammable and under pressure It should not be exposed to open flame sparks or hot engine components Allow the engine to cool to ambient temperature prior to changing fuel filters ac Fuel is under HIGH pressure consult dealer before servicing fuel system anne The bilge can accumulate explosive fumes The bilge blower will evacuate the fumes The bilge blower must be run for a minimum of 10 minutes prior to cranking the engine e Check fuel tank level See clear flood mode on page 18 e Check for signs of fuel leaks e Check fuel lines e Check fuel pressure Inspect for crimps kinks blockage or any disconnected lines Inspect for any leakage leaks may allow air in the lines blocking fuel flow e Follow and repair any leaks before continuing e Contact your service dealer for more advanced diagnosis e Check fuel pressure service dealer e Clean up any fuel spills or leaks prior to attempting to start the engine Engine Runs Hot anne Never remove the radiator cap under any condition while the engine is operating Failure to follow these instructions could result in damage to the cooling system engine or cause personal injury nn The bilge can accumulate explosive fumes The bilge blower will ev
53. ts for cracks and wear replace as necessary Inspect throttle control function Check for MIL at key on If MIL remains illuminated after starting it is indicating a fault refer to page 48 Check engine compression ENGINE COOLANT Check engine coolant level x Inspect coolant hoses for leaks cracks swelling or deterioration x x Replace coolant Inspect battery for case damage and corroded cables ENGINE ELECTRICAL SYSTEM Inspect electrical and ignition system Replace spark plugs FUEL SYSTEM Replace fuel water separator filter Check fuel pressure Service Dealer Inspect all fuel hoses and fittings for leaks AIR INTAKE Check for leaks in air intake and filtration system Inspect flame arrestor element x Clean flame arrestor element Clean or replace f ame arrestor element as condition s require or at 100 hours Inspect throttle body for loose bolts or vacuum leaks x ENGINE EXHAUST SYSTEM Inspect engine for exhaust leaks Inspect exhaust system for cracks leaks gaskets and loose bolts 26 CHANGING ENGINE OIL AND FILTER Under normal operating conditions the engine oil and filter must be changed every 100 hours or every 12 months whichever occurs first Use of premium quality oil and filters is recommended The oil and filter should be changed more often if the
54. uction you will learn how to take care of your engine and what services need to be performed to keep it in excellent running condition The table of contents will assist you in locating a specific subject Please contact a service dealer if you have reached a point of needing further instruction Any un authorized work can void any potential warranties We urge you to read this manual prior to start up of the engine KEM Equipment Inc engines are built with a variety of standard and or optional components to suit a broad range of customer requirements This manual does not identify equipment as standard or optional All the equipment described in this manual may or may not be found on your engine The description and specifications contained in this manual were in effect at the time of publication ENGINE IDENTIFICATION Model Identification An identification placard is affixed to the engine The label contains the engine family number and a model which identifies the engine from other KEM engines The engine model number and serial number are required when seeking information concerning the engine and or ordering replacement service parts KEM EQUIPMENT INC MAX RATED KW N 10800 SW HERMAN RD 4 TUALATIN OR 97062 SK 4 EMISSION CONTROL INFORMATION ENGINE FAMILY SERIAL NUMBER EXHAUST EMISSION CONTROL SYSTEM MODEL NO THIS ENGINE IS CERTIFIED TO OPERATE ON GASOLINE THIS MARINE ENGINE COMPLIES WITH U S EPA EXHAUST REGULATIONS FORA n
55. ull potential General engine specifications and quick reference guides starts on page 20 KEM Equipment Inc reserves the right to discontinue models or accessories at any time or to change specifications or designs without notice and without incurring obligation Please read and follow any and all specific Warnings Cautions and Notations contained in this text KEM Equipment Inc Kodiak Marine reserves the right to request any pertinent maintenance information of your engine prior to authorization of warranties Overall safety and equipment reliability depend on continuous observation of sound operating practices Always observe required scheduled maintenance activities as outlined Never attempt to correct problems or repairs for which you are not qualified At the end of this manual you will find a list of qualified Kodiak Marine service dealers to assist you in your area A WARNING Always STOP the engine before refueling Always STOP the engine prior to any inspection check or repair work Always maintain proper ventilation when working around gas or oil Always run the bilge blower for a minimum of 10 minutes prior to starting the engine Do not stand close or hover over the engine prior to starting Ensure all safety guards are in place prior to starting the engine How to Use this Manual This manual is designed to help you get to know your engine and become familiar with it s various controls During instr
Download Pdf Manuals
Related Search