KEM KODIAK MARINE User manual

KODIAK MARINE
Marine Operators Manual
4.3L 5.3L AND 6.2L SIDI INJECTED MARINE
ENGINES
KEM EQUIPMENT INC
10800 SW HERMAN RD
TUALATIN, OR. 97062
PHONE [phone]
FAX [phone] KM 10875

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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: 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.
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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.
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.
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.
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WARNING: Engine Damage may occur:All Generation V GM 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)
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.
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
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, 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 engine 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 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 8-9
Safety Summary
How to use this manual
SIDI Fuel Injection
Engine Identification Page 10-12
Engine ID
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 20-24
General Engine Specifications
Quick Reference Guide
Maintenance Schedule
Changing Engine Oil and Filter Page 25-26
Engine Oil Quality
Engine Oil recommendations
Oil Filter
Engine Spark Arrestor
Clean or Replace Flame Arrester
Cooling System Page 27-28
Heat Exchanger
Coolant Level
Serpentine Belt
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Fuel Injection System Page 29-30
Fuel Filter
Fuel Recommendation
Fuel Type
Fuel Quality Changes
Power Loss at Higher Elevations
Ignition System Page 31
Troubleshooting Page 32-36
Engine Does Not Crank
Engine Will Crank Intermittently
When the Engine Makes a Stuttering or Chattering Noise
Engine Cranks But will Not Start
Clear Flood Mode
Engine Runs Hot
Emissions
Storage Page 37
Short Term Lay-up
Long Term Lay-up
Periodic Maintenance Inspections Page 38-39
100, 400, 800, 900, Hour Inspections
Warranty Page 40-45
Powertrain On Board Diagnostic (OBD) System Check Page 46-47
Diagnostic Codes Page 48-57
Notice to Builders and Service Dealers Page 58
Service Dealer Locations Page 59-60
Wiring Diagrams Page 60-61
Engine Harness
Customer Interface Harness
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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 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 4.3L, 5.3L, AND THE 6.2L SIDI Direct Fuel
Injected 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 full potential. General engine specifications and quick reference guides
starts 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.
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.
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How to Use this Manual
This manual is designed to help you get to know your engine and become familiar with the
engines various controls. During instruction, 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 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
Direct injection moves the location of fuel entering the combustion chamber closer to the point
of ignition within the combustion chamber, this creates more combustion efficiency. This moves
to create a cleaner burn of fuel within the air fuel ratio mixture during the combustion cycle. The
results of this burn is lower exhaust port temperatures and a leaner mixture, meaning that a
considerable less amount of fuel is required to produce the same horsepower as a conventional
port fuel injection system.
WARNING: Engine Damage may occur:All Generation V GM 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)
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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.
This manual covers the 4.3L, 5.3L and the 6.2L SIDI Direct fuel Injected Marine Engines.
Fill in the information from your engine serial tag in the above representation of the engine
serial 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 department in fulfilling
your order. The serial number will confirm that you are ordering the correct parts for your
engine.
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Component Identification
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Component Identification
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 will vary from engine to engine.
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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 our Parts Department you can purchase parts and service manuals for Kodiak
Marine engines. 503-692-5012
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:
If the engine stalls or falters during starting, wait 3 to 4 seconds
before reengaging the s
tarter. 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.
Your KODIAK Marine Engine was inspected and test run before leaving the factory. Before
operating a new engine, you must follow any pre-operational instruction.
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, remove dipstick wiping clean and recheck your oil level.
4. Inspect the oil and fuel filters for tightness and making 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.
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.
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Inspect the spark arrester for any obstructions (Bugs, leaves etc.,) clean or Replace as needed.
11.Check the exterior of the heat exchanger. Follow and fix any leaks before continuing.
12.Check the alternator belt for any extra play; adjust as necessary. Does not apply to all
engines.
13.Tighten all loose nuts and bolts. Check for any loose pieces and tighten as necessary.
14.Start and run the bilge blower for at least 10 minutes.
15.Replace the engine cover.
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.
15

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. 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, fuel
pressure regulators, ignition system and Manifold Air Pressure (MAP) sensor 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 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 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.
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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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 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 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. 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.
WARNING: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.
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).
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MAINTENANCE INSTRUCTIONS
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.
CAUTION: Neglecting proper maintenance can cause premature component
failures.
Initial Start-Up Maintenance
The initial start-up checks must be made before entering the engine into service.
Please refer to the Maintenance Schedule on page 24 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, fuel and coolant leaks
• Repair any oil, fuel or coolant leaks
• Check battery condition and cables frequently clean as necessary
• Keep the engine air filter and/or spark arrestor clean
• Monitor engine coolant temperature
• Monitor engine oil pressure and fuel pressure.
• Check voltmeter and charging system
• Lubricate Drive Shaft universal joints as described in the scheduled preventive maintenance
section (some applications)
Knowing normal gauge values will help you determine any abnormal operating
conditions.
Maintenance Schedule
Refer to the Maintenance Schedule on page 24 to ensure that all of the maintenance items
listed are checked and replaced at the recommended hours.
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