KEM KODIAK MARINE LT4 SUPERCHARGED User manual

KODIAK MARINE
OPERATOR’S MANUAL
LT4 SUPERCHARGED ENGINE
KEM EQUIPMENT INC KM 11338
1
10800 SW HERMAN RD
TUALATIN, OR. 97062
PHONE [phone]
FAX [phone]
www.kemequipment.com

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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.
WARNING—DANGER OF DEATH OR PERSONAL INJURY
WARNING: Extreme High Fuel Rail Pressure
The SIDI Fuel Injectors and fuel rail have extreme high fuel pressures. Do not attempt to remove or
service these parts. This poses a potentially hazardous situation that if not avoided, could result in
severe personal injury or death, damage to engine and or property.
WARNING: 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.
WARNING: 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.

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WARNING: 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.
WARNING: ELECTRICAL SHOCK HAZARD
The ignition system can cause severe shock if proper precautions are not taken.
WARNING: 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.
CAUTION: POSSIBLE DAMAGE TO ENGINE OR PROPERTY
CAUTION: 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.

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CAUTION: 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 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.
CAUTION: ENGINE DAMAGE MAY OCCUR
All LT4 engines must be vacuum filled with coolant. If you need assistance or have questions call your
local service dealer. Failure to vacuum fill this engine with the recommended coolant may void all
warranty (See page 58 for instructions).
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 permanent damage to the ECM.

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CARBON MONOXIDE
WARNING: 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 poisonous 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 all produce carbon monoxide when burned.
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 exposure to carbon monoxide gases. It is important that regular inspections of the
exhaust system are performed and engine fresh air vents are kept clean and free of
obstructions.
Check that all maintenance is properly performed by a qualified technician. Adequate air
ventilation in all of the areas of your boat are necessary in order to prevent the build-up of
carbon monoxide gas.

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TABLE OF CONTENTS
Introduction Page 9-10
Safety summary
How to use this manual
SIDI fuel injection
Engine Identification Page 11-13
Model and serial number
Warranty registration
Component identification
Parts and service Page 14
Service literature
Pre Operational Inspection Page 15-17
Fluid levels, belts, battery connections, hoses, flame arrestor
Malfunction Indicator Light (MIL)
Starting the Engine Page 18-19
Starting mode fuel injection
Clear flood
Cold start
Stopping the Engine Page 20
Normal conditions
Abnormal conditions (overheating)
General Maintenance Page 21-24
Initial start-up Inspection
Routine maintenance
Quick reference chart
General specifications
Maintenance schedule
Changing Engine Oil and Filter Page 24-26
Engine oil level check
Adding engine oil
Engine oil quality
Engine oil recommendations
Oil filter
Flame arrestor
Cooling System Page 26-28
Coolant level
Engine heat exchanger
Intercooler heat exchanger
Serpentine belt

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Fuel Injection System Page 28-30
Fuel filter
Fuel pressure regulator
Fuel type
Fuel quality changes
Ignition System Page 30
Troubleshooting Page 30-34
Engine does not crank
Engine cranks, but only intermittently
Engine makes a stuttering or chattering noise when cranking
Engine cranks but does not start
Engine runs hot
Emissions
Storage or Lay-Up Page 35
Short term
Long term or indefinite period
Winterization
Periodic Maintenance Inspections Page 35-37
100, 300, 500, 700, and 900 hour inspections
400 and 800 hour inspections
Warranties Page 38-45
California emissions warranty
General emissions warranty
Kodiak Marine warranty
Exclusions
On Board Diagnostic (OBD) System Check Page 46-47
Diagnostic Error Codes Page 47-55
Marine Service Dealer Locations Page 56-57
Notices to Service Dealers and Boat Builders Page 58-62
Filling procedure
Fuel system installation instructions
Check Gauges light
High performance installation requirements
Wiring Diagrams Appendix A-B
Engine wiring harness schematic
Customer interface harness

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INTRODUCTION
KEM Equipment, Inc. is pleased you have selected a Kodiak Marine 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 engines.
Kodiak Marine 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 (pg 21).
This manual includes tables for General Engine Specifications and for General Maintenance.
Using this Manual will get you acquainted with your engine and its functions, as well guide routine
service and maintenance to keep your Kodiak Marine Engine performing to its full potential.
General engine specifications and quick reference charts start on page 21.
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. For the most up to date list, log on to
www.kemequipment.com .
SAFETY SUMMARY
WARNING: Safety Summary
-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.

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HOW TO USE THIS MANUAL
This Marine Operator’s Manual covers the LT4 6.2L Supercharged Direct Fuel Injection Marine
Engine. This manual is designed to help you get to know your engine and become familiar with
its various controls. This manual contains information to help you take care of your engine as well
as 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
startup 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.
SIDI FUEL INJECTION
SIDI stands for Spark Ignited Direct Injection. Direct injection moves the location of fuel entering
the combustion chamber closer to the point of ignition creating more combustion efficiency. This
causes a cleaner burn of fuel within the air fuel ratio mixture during the combustion cycle. The
results of this cleaner burn are lower exhaust port temperatures and a leaner mixture, meaning
considerably less fuel is required to produce the same horsepower as a conventional port fuel
injection system.