Kodiak KM10124 User manual

KODIAK MARINE
SUPERCHARGED
6.2L LSA
WARNING—DANGER OF DEATH OR PERSONAL INJURY
BY KEM EQUIPMENT INC.
KEM EQUIPMENT INC
10800 SW HERMAN RD.
TUALATIN, OR. 97062
PH# [phone]
FAX# [phone]
www.kemequipment.com
KM10124
REV-G
8/27/13

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Kodiak
Supercharged LSA Marine Engine
Critical Fuel System
Installation Instructions
For the Builder/Installer
We at 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 serviceable 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 Aero Motive 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 at 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 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: After all the fuel plumbing is complete, set the Initial fuel
pressure by cycling the ignition switch (key on/engine off) and adjust the setscrew on
the regulator until you are in the 65-psi range. This may take a few cycles of the key
switch for the fuel to fill the fuel lines, filter, and fuel rail. Check to make sure there are
no fuel leaks at all of the connections, tighten as necessary.
Once the vessel is in the water with the engine running at idle, you can now fine-tune the
fuel pressure to the target 65-psi Minimum, 67-psi Maximum pressure. After the fuel
pressure has been set, tighten the lock nut down on the fuel pressure regulator, and
double check for any fuel leaks in the fuel system.
Once the fuel pressure has been confirmed under a sea trials situation and the fuel
pressure is within the Minimum/Maximum setting described above, tamper proof the fuel
regulator adjustment screw. Tamper proof by using a small amount of tamper proof
compound, or an oil-based paint marker on the setscrew, locknut, and body of the
regulator.

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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: 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 present for safety, as appropriate
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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.
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.

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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.
IMPORT
ANT
DEFIN
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 9-10
How to use this Manual
ENGINE IDENTIFICATION Page 10-12
Model Identification
Component Identification
Parts and Service
Service Literature
MALFUNCTION INDICATOR LIGHT (MIL) Page 13
STARTING THE ENGINE Page 14
STOPPING THE ENGINE Page 15
Normal Conditions
MAINTENANCE INSTRUCTIONS Page 16-17
Initial Start Up Maintenance
Routine Maintenance
Scheduled Preventive Maintenance
Engine Oil Level Check
Add Engine Oil
CHANGING ENGINE OIL AND FILTER Page 17-18
Engine Oil Quality
Engine Oil Recommendation
Oil Filter
ENGINE FLAME ARRESTOR Page 18
COOLING SYSTEM Page 19-20
Cooling Level
Heat Exchanger
Heat Exchanger and Intercooler Plumbing
Oil Cooler Circuit
Serpentine Belt

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FUEL INJECTION SYSTEM Page 21-22
Fuel Pump
Fuel Filter
Fuel Pressure Regulator
FUEL RECOMMENDATIONS Page 23
Fuel Type
Fuel Quality Changes
Power loss at Higher Elevations
IGNITION SYSTEMS Page 24
Type of Ignition System
Spark Plugs
STORAGE Page 25
Short Term lay up one month
Long Term Indefinite Period
100,400,800 HOUR INSPECTIONS Page 26-27
TROUBLESHOOTING Page 28
DIAGNOSIS Page 29-31
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 32-33
Quick Reference Chart
General Engine Specifications
Maintenance Schedule
WARRANTY Page 34-35
Marine Warranty
DIAGNOSTIC ERROR CODES Page 37-45
SERVICE DEALERS Page 46-
47
SCHEMATICS Page 48-49
Engine Wiring Harness
Customer Interface Drawing

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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.
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 start-up inspection requirements in the Maintenance
section of this manual.
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.
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, 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.

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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
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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MALFUNCTION INDICATOR LIGHT
NOTE: A Check Engine or MIL light must be installed. 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.
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 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 Manifold Air Pressure (MAP) sensor.
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 before
continuing vehicle operation (after repairing the root problem).

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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. 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 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
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 33 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 33 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.
CHANGING OIL AND FILTER
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.
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
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.

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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 32 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.
ENGINE FLAME ARRESTOR
CAUTION: Service the flame arrestor more frequently under severely
dusty or dirty conditions.
Your flame arrestor filters air entering the engine induction system and acts as a
silencer. Air that contains dirt and grit produces an abrasive fuel mixture and can
cause severe damage to the cylinder walls and piston rings. Damage to the
cylinder walls and piston rings will cause high oil consumption and short engine
life. A restricted or dirty flame arrestor will also cause a rich fuel mixture.
Therefore it is extremely important that the flame arrestor be serviced at the
recommended intervals.
1. Clean screen by washing with solvent.
2. Blow dry or allow to drip dry prior to installation
3. Remove all dust and foreign matter from spark arrestor
4. Make sure the flame arrestor is seated properly on the throttle body and
secured with the proper clamp when reinstalling.

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COOLING SYSTEM
WARNING: 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.
CAUTION: DO NOT add coolant to any engine that has become
overheated until the engine cools. Adding coolant to an extremely hot
engine can result in a cracked block or cylinder head.
Coolant Level
CAUTION: 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
temperatures), but replace it with the specified coolant as quickly as
possible to avoid damage to the system.
KEM Equipment and General Motors recommends the use of DEX-COOL only.
Do not use alcohol or methanol antifreeze, or mix them with specified coolant.
Plain water may be used in an emergency, but replace it with the specified
coolant as quickly as possible to avoid damage to the system. Do not let the
engine run hot with only water acting as the primary coolant.
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.
Heat Exchanger
1. Check the coolant level in the heat exchanger daily (prior to operation)
2. Make sure the coolant level is within ¾ to 1 ½ inches below the filler neck seat
3. Check the condition of the rubber seal on the coolant filler cap
4. Make sure the rubber seal is clean and free of any dirt particles.
5. Make sure the filler neck is clean then replace cap.
6. Check all hoses and connections for leaks.
7.Check all hoses and belts for cracks, frayed points, or spongy areas (replace
as necessary).

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Heat exchanger and Intercooler Plumbing
Serpentine Belt
Some GM Powertrain engines utilize serpentine belts on the front of the engine.
This type of belt system incorporates a belt-tensioning device that keeps the belt
adjusted to the proper tension. No manual adjustments are necessary.
This belt should be checked routinely for cracks or ‘checking’ on the groove side
of the belt. If cracks or ‘checking’ are apparent the belt must be changed.