KEM KODIAK MARINE User manual

KODIAK MARINE
CERTIFIED
SUPERCHARGED
6.2L LSA
ERSONAL INJURY
KEM EQUIPMENT INC
10800 SW HERMAN RD.
TUALATIN, OR. 97062
PH# [phone]
FAX# [phone]
www.kemequipment.com KM10929

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Kodiak
Supercharged LSA Marine Engine
Critical Fuel System
Installation Instructions
For the Builder/Installer
KEM Equipment Inc. would like to congratulate you on your decision to recommend the
Supercharged LSA Marine engine to your valued customer.
The Kodiak 6.2L LSA Supercharged Marine fuel system, once properly set up, will give
your customer many years of trouble free service.
The Fuel System Installation Instructions need to be read and followed prior to start up
and operation of the 6.2L Supercharged Marine Engine. Failure to follow these
instructions during set up of the Fuel System may result in a catastrophic failure of the
Engine and may also VOID the Engine warranty.
Below are some specific installation procedures and guide lines that need to be followed
very closely to complete the installation of the fuel system for the 6.2L Supercharged
LSA Marine engine.
If you are unsure of, or need assistance with these instructions, feel free to call
KEM Equipment at 503-692-5012
WARNING: 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 performing fuel system modifications or fuel
system maintenance.
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.

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Plumbing: The fuel supply pick up tube, fuel lines, and fittings shall be no smaller than ½”
inside diameter between the fuel tank and Aero Motive high-pressure fuel pump. The fuel pump
must also have the supplied 100 Micron filter installed on the inlet side of the fuel pump.
When using an auxiliary engine such as an outboard motor, never plumb or tee into the main
engine fuel system. The auxiliary engine shall have its own fuel pick up tube and fuel filter/water
separator from the fuel tank. Plumbing into the main engine fuel supply will cause damage to
the engine and fuel pump system.
Fuel pump placement: The AeroMotive fuel pump must be placed as close to the fuel tank as
possible. A 30” Maximum distance from the fuel tank outlet to the fuel pump inlet shall not be
exceeded.
The fuel pump must also be placed as low to the bottom of the fuel tank as possible. Using the
lowest point on the bottom of the fuel tank, mount the fuel pump a Maximum vertical distance
of 12” from the bottom of the fuel tank. Check for any laws and/or restrictions that may apply.
The Racor fuel /water separator should NEVER be placed on the outlet side of the high-
pressure fuel pump. The Racor fuel filter/water separator shall also be mounted within a
Maximum distance of 12” vertical from the bottom of the fuel tank.
Hoses: Use only USCG Approved fuel lines. Check for any laws and/or restrictions that may
apply. Check when routing the fuel lines that they are not laying over, or rubbing against any
sharp edges.
Fittings: When choosing fittings, the use of a 90°full flow design is preferable over the
restricted tight 90°fittings.
Setting the fuel pressure: The fuel pressure regulator is non-adjustable and has been factory
sealed as required by EPA regulations. Any attempt to change the fuel pressure settings on
the fuel pressure regulator will void all warranties for this engine.
Once the vessel is in the water with the engine running at idle, verify with Diacom the target fuel
pressure 65-psi Minimum, 67-psi Maximum pressure. After the fuel pressure has been
verified, double check for any fuel leaks in the fuel system.
Once the fuel pressure has been confirmed using Diacom, and the fuel pressure is at the
recommended pressure Minimum/Maximum, run the engine in a sea trials situation. Verify the
system is not leaking at any fitting or hose connection. If the fuel pressure does not fall within
the Minimum/Maximum allowed pressure, contact your nearest service dealer for assistance.

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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 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 exposure 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.
CAUTION: TO MEET EPA and CARB REQUIREMENTS:
ALL KODIAK CERTIFIED MARINE ENGINES SOLD AFTER JANUARY 2007 MUST HAVE A
CHECK ENGINE AND CHECK GAUGES LAMP.A CAN CONTROL GAUGE MAY BE
SUBSTITUTED IF THIS GAUGE WILL SET A FAULT LAMP IN THE EVENT OF AN
EMISSIONS RELATED, OR VITAL ENGINE COMPONENT FAILURE.
FAILURE TO INSTALL THESE MALFUNCTION INDICATOR LIGHTS WILL VOID ALL
ENGINE WARRANTIES.
The wiring schematics included in the Kodiak Marine Operators Manuals show the
correct wiring at the ECM and the Customer Interface Connector. TAG PART #
KM10539 IS INSTALLED AT THE STARTER ON THE BATTERY CABLE TERMINAL AS A
CAUTION; NOTICE TO INSTALLER.
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.

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WARNING: ELECTRICAL SHOCK HAZARD
The ignition system can cause severe shock if proper precautions are not taken.
WARNING: OVERSPEED PROTECTION
The engine is equipped with an overspeed shutdown mode to protect against
damage to the engine with possible personal injury, loss of life, or property
damage. The overspeed shutdown is totally independent of the operators control
system. An over temperature or overpressure shutdown mode is also be present
for safety, as appropriate.
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.
ON—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.
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.
IMPORTEF

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A WARNING: indicates a potentially hazardous situation, which, if not
avoided, could result in death or serious injury.
A CAUTION: indicates a potentially hazardous situation, which, 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.

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TABLE OF CONTENTS
INTRODUCTION Page 10
How to use this Manual
ENGINE IDENTIFICATION Page 12-14
Model Identification
Parts and Service
Service Literature
Component Identification
MALFUNCTION INDICATOR LIGHT (MIL) Page 15
STARTING THE ENGINE Page 16
STOPPING THE ENGINE Page 17
Normal Conditions
MAINTENANCE INSTRUCTIONS Page 18-19
Initial Start Up Maintenance
Routine Maintenance
Scheduled Preventive Maintenance
Engine Oil Level Check
Add Engine Oil
CHANGING ENGINE OIL AND FILTER Page 20
Engine Oil Quality
Engine Oil Recommendation
Oil Filter
ENGINE FLAME ARRESTOR Page 21
COOLING SYSTEM Page 22-23
Cooling Level
Heat Exchanger
Heat Exchanger Plumbing
Inter Cooler Circuit
Oil Cooler Circuit
Serpentine Belt

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FUEL INJECTION SYSTEM Page 24-26
Fuel Pump
Fuel Filter
Fuel Pressure Regulator
Fuel Pressure
Fuel Recommendations
Fuel Type
Fuel Quality Changes
Power Loss at Higher Elevations
IGNITION SYSTEMS Page 27
Type of Ignition System
Spark Plugs
STORAGE Page 28-31
Lay up
Inspections
TROUBLESHOOTING Page 32
DIAGNOSIS Page 33-35
Engine Does Not Crank
Engine Will Crank Intermittently
When Engine Makes A Stuttering Or Chattering Noise
Engine Cranks But Will Not Start
Engine Runs Hot
SPECIFICATIONS Page 36-37
Quick Reference Chart
General Engine Specifications
Maintenance Schedule
WARRANTY Page 38-39
Marine Warranty
DIAGNOSTIC ERROR CODES Page 40-49
SERVICE DEALERS Page 50-51
SCHEMATICS Page 52-53
Engine Wiring Harness
Customer Interface

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INTRODUCTION
Please read and follow any and all specific Warnings, Cautions and Notes that are
contained in this manual.
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./ 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.
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.
To help protect the starter and electrical components, make sure the bilge is free
of excessive water.
All 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 pre start-up inspection requirements in the Maintenance
section of this manual on page 37.
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.

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How to Use this Manual
This manual contains instructions on the safe operation and preventive maintenance of
your Kodiak marine engine. We urge you to read this manual prior to start up of the
engine.
The Table of Contents permits you to quickly open the manual to any section. 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. KEM Equipment, Inc. reserves the right to discontinue models at any time,
or to change specifications or design without notice and without incurring obligation.

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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.
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 or parts for this engine
Parts and Service
Replacement parts can be obtained through your local Kodiak engine dealer.
Kodiak dealers are equipped to perform major and minor repairs. The dealer personnel
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.
Technical support for Kodiak Marine engines can be obtained by contacting KEM
Equipment Inc. 503-692-5012
Service Literature
By contacting our Parts Department you can purchase parts and Service manuals for
Kodiak Marine engines. 503-692-5012

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Component Identification

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1 HEAT EXCHANGER (INTERCOOLER/OIL COOLER)
2 HEAT EXCHANGER (ENGINE MAIN)
3 WATER PUMP (INTERCOOLER)
4 RESERVOIR (INTERCOOLER)
5 PUMP / HEAT EXCHANGER MOUNT
6 COOLANT TEE
7 COOLANT TRANSFER PIPE (OUT)
8 COOLANT TRANSFER PIPE (IN)
9 COOLANT OVERFLOW RESERVOIR
10 COIL PACK
11 MEFI V ECM
12 ECM VIBRATION ISOLATORS
13 RELAY/FUSE BOX
14 50 AMP RELAY (CIRCUIT BREAKER)
15 REMOTE OIL FILTER BASE
16 OIL FILTER
17 HI MOUNT STARTER (OPTION)
18 BELLHOUSING
19 LOW MOUNT STARTER (STANDARD)
20 EXHAUST MANIFOLD
21 RISER GASKET
22 RISER (4")
23 ENGINE MOUNT
24 ENGINE DRIVE BELT
25 SUPERCHARGER DRIVE BELT

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MALFUNCTION INDICATOR LIGHT
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.
One warm up cycle is a starting temperature close to ambient increasing to
operating temperature.
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 Malfunction Indicator Light (MIL). The MIL conveys to the operator that a
fault exists that is related to the engine’s control system. When the MIL light is
illuminated a fault code has been set that requires immediate attention, engine
component damage could conceivably occur. Please stop operation of engine as
soon as safely possible. Continued operation of the engine with a MIL or Check
Gauges light illuminated, may cause catastrophic damage to the engine or may
cause an accident resulting in injury or death. Request that a service technician
inspect the fault code setting. He or she will connect a scan tool to determine the cause
of the MIL to illuminate, diagnose and repair the problem, clear the codes. Test run the
vessel to make sure the issue has been corrected. 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 Manifold Air Pressure (MAP)
sensor and throttle position sensors.
The second indicator is the Check Engine 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 relays 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 turn off the
engine 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.
Similar to the MIL, the fault code will have to be read and cleared by a service dealer
technician before continuing with operation of the vessel.

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STARTING THE ENGINE
Prior to starting the engine the following must be performed.
Check engine oil
level.
Check for fuel leaks.
Run bilge blower for a minimum of 10 minutes.
Run bilge pump to remove any excess water, follow and repair any leaks.
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: All internal combustion engines give off various fumes and
gases while running. Do not start or run the engine in a closed or poorly
ventilated area where exhaust gases may accumulate.
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.
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.
If the engine is equipped with a stern drive 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.

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STOPPING THE ENGINE
WARNING: The engine may continue to run after ignition is turned off, turn
the ignition switch immediately to ON and allow the engine to idle until it has
cooled enough to stop.
WARNING: Avoid injury when checking a hot engine. Allow the engine to
cool down before removing the heat exchanger cap.
CAUTION: Before restarting the engine ensure that both the coolant system
and the engine oil level have been checked and re-filled if necessary.
Normal Conditions
Following normal operating conditions, lower the engine speed to idle, pushing the
throttle cable in on mechanical systems or with electronic systems return to idle. Put the
drive in neutral. Run the engine for a few minutes at idle to allow the coolant system to
cool down before turning the ignition switch to the off position.

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MAINTENANCE INSTRUCTIONS
CAUTION: Neglecting proper maintenance can cause premature engine
component failures.
Initial Start-Up Maintenance
The initial start-up checks must be made before putting the engine into service.
Please refer to the Maintenance Schedule on page 37 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:
• 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.
• Make frequent checks for engine oil and coolant leaks
• Repair any oil or coolant leaks
• Check battery condition and cables frequently
• Keep the engine air filter and/or spark arrestor clean
• Monitor engine coolant temperature
• Monitor engine oil pressure
• Check voltmeter and charging system
• Monitor fuel pressure
Scheduled Preventive Maintenance
Refer to the Maintenance Schedule on page 37 to ensure that all of the maintenance
items listed are checked and replaced at the recommended hours.
Engine Oil Level Check
CAUTION: 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.
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.

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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.
NOTE: Use only Mobil 1 5W-30 full synthetic or equivalent motor oil. When
changing the 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 a premium quality oil and filters
is recommended.
The oil and filter should be changed more often if the engine is operating in severe
conditions, such as dirty areas, or during cold weather. No oil additives or break-in oil
are recommended.

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CHANGING ENGINE OIL AND FILTER
Engine Oil Quality
NOTE: 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
Mobil 1 5W-30 full synthetic or equivalent synthetic motor oil must be used in the
supercharged marine engine.
Motor oils meeting ILSAC (International Lubricant Standardization & Approval
Committee) GF-5 standards. The GM spec for this oil is GM 4718M OR GM6094M.
Motor oils meeting this spec receive the API (American Petroleum Institute) Starburst
and the Dexos 1 symbols.
Oil Filter
NOTE:Ensure the old filter gasket is removed prior to installing 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 the
Engine Specification on page 36 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 ½ 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.