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.

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ENGINE IDENTIFICATION
MODEL IDENTIFICATION AND SERIAL NUMBER IDENTIFICATION
An identification placard is affixed to the engine. The placard contains the engine family number,
model number, and serial number. Both the engine model number and serial number are required
when seeking information concerning the engine and/or ordering replacement service parts.
This manual covers the LT4 6.2L Marine Engine. You can fill in the information from your engine
identification placard in the above representation for future reference.
Model: This is the part number for the engine. This number should be recorded somewhere other
than the boat for ease of obtaining information or parts for this engine.
Serial Number: This number identifies each individual engine. This number should also be
recorded somewhere other than in the boat. If you have a request or need to order service parts,
this serial number will be requested to aid our parts department in fulfilling your order. The serial
number will confirm that you are ordering the correct parts for your engine.
WARRANTY REGISTRATION
The warranty registration card shipped with your engine must be filled out and returned to KEM
Equipment, Inc./Kodiak Marine within 10 days of receipt of your new vessel. The warranty card
can be emailed to [e-mail] , faxed to [phone], or mailed to 10800
SW Herman Rd Tualatin, OR 97062. 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 registration card to KEM Equipment, Inc. 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.

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COMPONENT IDENTIFICATION
Exhaust Riser
Coolant transfer pipe
Remote oil filter
MEFI 7 ECM
50 AMP circuit breaker
Flame arrestor
Coolant overflow reservoir
Exhaust manifold
Supercharger drive belt
Heat exchanger pressure cap
Water pump
Alternator
O
2
sensor
Intercooler pressure cap

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COMPONENT IDENTIFICATION CONTINUED
The illustrations above show the general location of engine controls, engine components and
their functions. These illustrations will help identify where these parts are located on the engine.
Locations may vary from engine to engine.
Heat exchanger
Oil cooler
Starter
Intercooler Pump
Relay and Fuse box
Thermostat housing
Customer Interface Connector

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PARTS AND SERVICE
Replacement parts can be obtained through your local Kodiak Marine engine dealer. Kodiak
dealers are equipped to perform major and minor repairs. They hope to see all of your
maintenance and service needs are quickly and courteously completed. Feel free to contact KEM
Equipment Inc./Kodiak Marine regarding your experiences with our service dealers, good or bad.
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 near the end of this manual. Or you can
log on to www.kemequipment.com for the most up to date service dealer list.
Some part numbers commonly used in general maintenance are listed in the LT4 Engine Quick
Reference table on page 21 of this manual.
SERVICE LITERATURE
By contacting our Parts department at 503-692-5012, you can purchase parts and service
manuals for Kodiak Marine engines. A parts book and a digital copy of this manual are also
available online at kemequipment.com
WARNING: The bilge and engine compartment 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.
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 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.

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PRE-OPERATIONAL INSPECTION
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.
Before operating your engine, you must perform a pre-operational inspection.
1. Open the engine hatch cover to let the compartment air out for at least ten minutes.
2. Always make sure you are working in a well-ventilated area when around gasoline.
3. Check engine oil level by removing dipstick, wiping it clean, and re-inserting it to check your
oil level.
4. Inspect the oil and fuel filters for tightness and ensure there are no leaks around filters.
5. Check coolant levels – refill to the appropriate levels.
6. Check for any oil, coolant, or fuel leaks.
CAUTION: Follow any leaks and repair any abnormal leakage before continuing.
7. Inspect the flame arrestor for any obstructions (bugs, leaves etc.,) clean or replace as needed.
8. Check the battery fluid level and state of charge, fill as needed.
9. Inspect the battery connections for corrosion and clean if necessary
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.
10. Check the exterior of the heat exchanger. Follow and fix any leaks before continuing.
11. Check the alternator belt for cracks and the tensioner for any extra play; fix as necessary
before continuing.
12. Tighten all loose nuts and bolts. Check for any loose pieces and tighten as necessary.
13. Start and run the bilge blower for at least 10 minutes.
14. Replace the engine cover.

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MALFUNCTION INDICATOR LIGHT
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 acknowledge any illuminated Check Engine or Check Gauges lights during the
course of engine operation.
The first indicator is the Check Engine Light or Malfunction Indicator Lamp (MIL). 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, they will connect a scan tool to determine what caused the MIL to
illuminate, repair the problem, and clear the code(s). The MIL related codes are caused by
sensor output and/or conditions that adversely affect the operational output of the engine. Some
components to check or issues that can cause the MIL to illuminate are: crank sensor, cam
sensor, fuel injectors, fuel pressure regulators, ignition system, Manifold Air Pressure (MAP)
sensors, or low fuel pressure.
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
normal operating temperature.
The second indicator light on the dash 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, high or low coolant temperature, various power relay operations, 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

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is out of the normal range e.g., low oil pressure when the engine is at rated speed. If the engine
should turn off for no apparent reason, check this lamp. This light will clear on its own if the fault
clears and the ignition switch is turned off then back on. If this light turns off on its 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 vessel manufacturers are using CAN-BUS displays that can retrieve the error
codes, but cannot clear them. See the vessel manufacturer’s instructions to retrieve the error codes
with their device.

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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
WARNING: 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.
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: 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.

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CAUTION: If the engine stalls or falters during starting, 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.
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.
STARTING MODE–FUEL INJECTION
With the ignition switch in the ON position, before engaging the starter, the Engine Control
Module (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 temperature/manifold absolute pressure (TMAP) 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 idle speed will gradually
decrease. This is a normal engine control function.

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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. Once the engine has cooled considerably, check and adjust the oil and coolant levels.
6. When the engine has completely cooled, add your coolant slowly until the heat exchanger is
full.
WARNING: Allow the engine to cool completely 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.
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).
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