KEM KODIAK MARINE Operator'S Manual Download

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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 (503) 692-5012
FAX (503) 692-1098                                                              KM 10875

Summary of Contents for KODIAK MARINE

Page 1: ...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 503 692 5012 FAX 503 692 1098 KM 10875 ...

Page 2: ...2 ...

Page 3: ...nt 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 e...

Page 4: ... 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...

Page 5: ... 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 fo...

Page 6: ...tarting 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 R...

Page 7: ...tering 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...

Page 8: ...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 a...

Page 9: ...l 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...

Page 10: ... 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...

Page 11: ...Component Identification 11 ...

Page 12: ...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 12 ...

Page 13: ...ice 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 ga...

Page 14: ... 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 obstruction...

Page 15: ...rnator 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 ...

Page 16: ...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 th...

Page 17: ...in 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 ignit...

Page 18: ... 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 EC...

Page 19: ... 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 a...

Page 20: ... 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 e...

Page 21: ... WATER SEPERATOR FILTER NAPA 3225 SERPENTINE BELT NAPA 25 060716 FUEL PRESSURE BEFORE FUEL RAIL 4 BAR 58 PSI FUEL TYPE REGULAR UNLEADED RECOMMENDED ENGINE OIL 0W 20 DEXOS 1 GM SPEC 15827 4 3L VVT DIRECT INJECTED MARINE ENGINE SPECIFICATIONS DISPLACEMENT 4301cc 262 ci ENGINE ORIENTATION LONGITUDINAL COMPRESSION RATIO 11 0 1 VALVE CONFIGURATION OVERHEAD VALVE VALVES PER CYLINDER 2 VALVE LIFTERS HYDR...

Page 22: ...R SEPERATOR FILTER NAPA 3225 SERPENTINE BELT NAPA 25 060716 FUEL PRESSURE BEFORE FUEL RAIL 4 BAR 58 PSI FUEL TYPE REGULAR UNLEADED RECOMMENDED ENGINE OIL 0W 20 DEXOS 1 GM SPEC 15827 5 3L VVT DIRECT INJECTED MARINE ENGINE SPECIFICATIONS DISPLACEMENT 5328cc 325 ci ENGINE ORIENTATION LONGITUDINAL COMPRESSION RATIO 11 0 1 VALVE CONFIGURATION OVERHEAD VALVE VALVES PER CYLINDER 2 VALVE LIFTERS HYDRAULIC...

Page 23: ...SEPERATOR FILTER NAPA 3225 SERPENTINE BELT NAPA 25 060716 FUEL PRESSURE BEFORE FUEL RAIL 4 BAR 58 PSI FUEL TYPE PREMIUM UNLEADED ONLY RECOMMENDED ENGINE OIL 0W 20 DEXOS 1 GM SPEC 15827 6 2L VVT DIRECT INJECTED MARINE ENGINE SPECIFICATIONS DISPLACEMENT 6162cc 376 ci ENGINE ORIENTATION LONGITUDINAL COMPRESSION RATIO 11 5 1 VALVE CONFIGURATION OVERHEAD VALVE VALVES PER CYLINDER 2 VALVE LIFTERS HYDRAU...

Page 24: ... engine compression X ENGINE COOLANT Check engine coolant level X Replace coolant X Inspect coolant hoses for leaks cracks swelling or deterioration X X X ENGINE ELECTRICAL SYSTEM Inspect battery for case damage and corroded cables X X Inspect electrical and ignition system X X Replace spark plugs X FUEL SYSTEM Replace fuel water separator filter X Check fuel pressure Service Dealer Inspect all fu...

Page 25: ...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 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 specificat...

Page 26: ...ry to stop any oil leakage Flame Arrester The purpose of the flame arrestor is to contain any possible flame that gets into the intake manifold due to an engine failure but also serves other purposes 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 contain...

Page 27: ...ater 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...

Page 28: ...ons for leaks 7 Check coolant overflow tank level fill to cold line prior to operation 8 Check all hoses for cracks frayed points or spongy areas replace as necessary Serpentine Belt NOTE Make sure the belt tensioner is within the proper operating range Kodiak Marine engines utilize serpentine belts on the front of the engine This type of belt system incorporates a belt tensioning device that keep...

Page 29: ...ngine components Allow the engine to cool to ambient temperature prior to changing fuel filters WARNING Fuel is under Extreme HIGH Pressure consult equipment service dealer before servicing any part of the fuel system 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 Fuel W...

Page 30: ...el Quality Changes NOTE Sudden changes in fuel quality including geographical regions may effect engine operation Power Loss at Higher Elevations Fuel injected engines will lose 3 5 power for every 1000 feet the engine is operated above sea level All fuel injection systems installed by KEM Equipment Inc are equipped with a manifold absolute pressure sensor MAP Sensor The MAP sensor senses barometr...

Page 31: ...er plugs or similar plugs that are not exact equivalents to the recommended plugs can cause permanent engine damage reduce the engines useful life and cause many other problems such as hard starting spark knock and run on premature failure of catalyst and exhaust emissions may occur Spark plugs should be replaced at the recommended intervals as described in the Maintenance Schedule on page 24 Use ...

Page 32: ...wing list should cover the most common problems Loose or corroded battery connections are more common than battery failure Loose ignition wire connection more common than distributor coil or ignition Severe weather conditions temps below 32 F 0 C can cause condensation on the inside of the engine Operating conditions load changes Change of periodic servicing Change of grade or purity of fuel Conta...

Page 33: ... Check all fuses and relays Refer to Pre Operational checklist for further checks Engine Will Crank Intermittently Having to turn the key to START several times Check the ignition switch for loose corroded disconnected or broken wires Tighten or replace as necessary When The Engine Makes A Stuttering Or Chattering Noise Check the battery cables for loose connections Check battery charge charge if ...

Page 34: ...poses a potentially hazardous situation that if not avoided could result in severe personal injury or death damage to engine and or property 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 Check fuel tank level See clear flood mode on page 18 Check for signs of fuel leaks...

Page 35: ...coolant or water to an extremely hot engine can result in a cracked block or cylinder head The following items may cause the engine to overheat Low coolant level Loose or broken belt Inoperative thermostat Inoperative water pump seawater or circulation or sand trap Clogged inlet strainer seawater or circulation from jet drive Clogged heat exchanger tube s Low oil level Ruptured plugged or kinked h...

Page 36: ...itute 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 This engine is certified for inboard use only in jet drive and stern drive vessels Installation of this engine in outboard applications is a violation of the Clean Air Act This engine and the installed system com...

Page 37: ...re drained when ambient temperature is or may go below 32 F 0 C STORAGE Lay Up FOR INDEFINITE PERIOD 1 Add proper amount of marine formula Stabil fuel additive or equivalent to the fuel tank 2 Drain oil from crankcase refill with recommended engine oil SAE 10W40 or equivalent 3 Shut off ignition switch 4 Check coolant protection and fluid levels 5 Disconnect and remove battery 6 Leave spark plugs ...

Page 38: ...e blower Let blower run for 10 minutes 12 Close engine cover 400 Hour Inspection WARNING Make sure key is not in the ignition and no electrical equipment is energized prior to any engine check or operation Do not energize engine prior to performing the following steps 1 Open engine hatch cover and let compartment air out for ten minutes or more 2 Make sure that no electrical equipment is energized...

Page 39: ...battery Inspect connections for corrosion and clean as necessary 6 Check flame arrestor Make sure that it is cleaned replaced as necessary 7 Inspect the exterior of the heat exchanger clean if necessary 8 Check alternator belt adjust if necessary 9 Remove and replace fuel filter 10 Remove clean adjust test and or replace spark plugs 11 Remove and replace PCV valve if applicable 12 Drain and replac...

Page 40: ...ars If any emission related part on your engine is defective under warranty the part will be repaired or replaced by KEM Equipment Inc Kodiak Marine OWNER S WARRANTY RESPONSIBILITIES As the inboard stern drive engine owner you are responsible for the performance of the required maintenance listed in your owner s manual KEM Equipment Inc Kodiak Marine recommends that you retain all receipts coverin...

Page 41: ...rding to Subsection 4 below Any such part repaired or replaced under warranty will be warranted for the remainder of the period 2 Any warranted part that is scheduled only for regular inspection in the written instructions supplied is warranted for the warranty period stated above Any such part repaired or replaced under warranty will be warranted for the remaining warranty period 3 Any warranted ...

Page 42: ...m made in accordance with these warranty procedures and Policies KEM Equipment Inc Kodiak Marine will not be liable under these warranty procedures and policies to warrant failures of warranted parts caused by the use of a non exempted add on or modified part Following is a list of those critical emission related parts that are covered under the provisions of this emission warranty 1 Fuel Metering...

Page 43: ...ment of the part Except as provided in the paragraph above any adjustment of a component that has a factory installed and properly Operating Adjustment limiting device such as an idle limiter cap or plug is eligible for warranty coverage under General Emissions Warranty Coverage above Non Commercial Applications Starters Alternators and Fuel pumps will be warranted for a period of 2 years or 200 h...

Page 44: ...exceed three 3 years or 480 hours whichever occurs first measured from the original retail sale date All subsequent purchasers must inform Kodiak in writing and with a payment of 100 00 transfer fee to continue the warranty If Kodiak does not receive notification and payment within 15 days of the resale the warranty will be null and void Third year 3 of the warranty period is limited to defects in...

Page 45: ...AL COMPONENTS CORROSION DUE TO ELECTROLYSIS WATER BORN FOREIGN CHEMICALS IMPROPER SERVICE OR CORROSION CAUSED BY DAMAGE OR ABUSE REIMBURSEMENT FOR TOWING CHARGES IN AND OUT OF WATER CHARGES OR TECHNICIAN TRAVEL TIME GROWTH OF MARINE ORGANISMS ON MOTOR SURFACES EXTERNAL OR INTERNAL DISCLAIMER OF CONSEQUENTIAL DAMAGE AND LIMITATION OF IMPLIES WARRANTIES Kodiak Marine DISCLAIMS ANY RESPONSIBILITY FOR...

Page 46: ...ere personal injury or death damage to engine and or property 1 Verify that none of the following preliminary inspections tests reveal the cause of the vehicle concern before beginning diagnosis Ensure that the battery is fully charged Ensure that the battery cables are clean and tight Inspect for any open fuses Ensure that the grounds are clean tight and in the correct location Inspect the easily...

Page 47: ...es not crank refer to SPN 66001 or SPN 66002 if equipped If the engine is not equipped with an ECM controlled starter relay repair the starting system Attempt to start the engine Verify the engine starts and idles Important Do not clear any SPNs unless instructed to do so by a diagnostic procedure Use the appropriate scan tool selections to obtain SPNs from each of the vehicle modules Verify there...

Page 48: ...ine Oil Pressure EOP Sensor Circuit Voltage Below Normal or Shorted Low SPN 100 FMI 17 Engine Oil Pressure EOP Sensor Data Valid But Below Normal Range Least Severe Level SPN 105 SPN Descriptors SPN 105 FMI 3 Manifold Air Temperature MAT Sensor Circuit Voltage Above Normal or Shorted High SPN 105 FMI 4 Manifold Air Temperature MAT Sensor Circuit Voltage Below Normal or Shorted Low SPN 106 SPN Desc...

Page 49: ...vere Level SPN 174 SPN Descriptors SPN 174 FMI 3 Fuel Temperature FT Sensor Circuit Voltage Above Normal or Shorted High SPN 174 FMI 4 Fuel Temperature FT Sensor Circuit Voltage Below Normal or Shorted Low SPN 627 SPN Descriptor SPN 627 FMI 15 System Voltage Data Valid But Above Normal Range Least Severe Level SPN 627 FMI 17 System Voltage Data Valid But Below Normal Range Least Severe Level SPN 6...

Page 50: ...tors SPN 65541 FMI 4 Ignition Coil 1 Voltage Below Normal or Shorted Low SPN 65541 FMI 5 Ignition Coil 1 Current Below Normal or Open Circuit SPN 65542 FMI 4 Ignition Coil 2 Voltage Below Normal or Shorted Low SPN 65542 FMI 5 Ignition Coil 2 Current Below Normal or Open Circuit SPN 65543 FMI 4 Ignition Coil 3 Voltage Below Normal or Shorted Low SPN 65543 FMI 5 Ignition Coil 3 Current Below Normal ...

Page 51: ...ensor Bank B Sensor 1 Data Valid But Below Normal SPN 65563 FMI 3 Oxygen Sensor Bank B Sensor 1 Voltage Above Normal or Shorted High SPN 65563 FMI 4 Oxygen Sensor Bank B Sensor 1 Voltage Below Normal or Shorted Low SPN 65563 FMI 5 Oxygen Sensor Bank B Sensor 1 Current Below Normal or Open Circuit SPN 65564 FMI 0 Oxygen Sensor Bank B Sensor 2 Data Valid But Above Normal SPN 65564 FMI 1 Oxygen Senso...

Page 52: ...FMI 7 Misfire Cylinder 8 Mechanical System Not Responding or Out of Adjustment SPN 65599 FMI 7 Misfire Random Mechanical System Not Responding or Out of Adjustment SPN 65601 65602 or 65610 SPN Descriptors SPN 65601 FMI 2 Throttle Position TP Sensor 2 Data Erratic Intermittent or Incorrect SPN 65602 FMI 2 Throttle Position TP Sensor 1 Data Erratic Intermittent or Incorrect SPN 65610 FMI 2 Throttle ...

Page 53: ...672 FMI 3 Catalytic Converter B Temperature Sensor Voltage Above Normal or Shorted High SPN 65672 FMI 4 Catalytic Converter B Temperature Sensor Voltage Below Normal or Shorted Low SPN 65673 or 65674 SPN Descriptors SPN 65673 FMI 15 Catalytic Converter A Temperature Sensor Data Valid But Above Normal Range Least Severe Level SPN 65674 FMI 15 Catalytic Converter B Temperature Sensor Data Valid But ...

Page 54: ...PN 66001 FMI 3 Starter Relay Low Side Driver Voltage Above Normal or Shorted High SPN 66001 FMI 5 Starter Relay Low Side Driver Current Below Normal or Open Circuit SPN 66002 SPN Descriptor SPN 66002 FMI 4 Starter Relay High Side Driver Voltage Below Normal or Shorted Low SPN 66002 FMI 5 Starter Relay High Side Driver Current Below Normal or Open Circuit SPN 66003 SPN Descriptor SPN 66003 FMI 3 Ma...

Page 55: ...66008 FMI 5 DTC Lamp 1 Current Below Normal or Open Circuit SPN 66009 SPN Descriptor SPN 66009 FMI 3 DTC Lamp 2 Voltage Above Normal or Shorted High SPN 66009 FMI 5 DTC Lamp 2 Current Below Normal or Open Circuit SPN 66010 SPN Descriptor SPN 66010 FMI 3 Slow Mode Lamp Voltage Above Normal or Shorted High SPN 66010 FMI 5 Slow Mode Lamp Current Below Normal or Open Circuit SPN 66013 or 66014 SPN Des...

Page 56: ...lse Width SPN 66021 or 66022 SPN Descriptors SPN 66021 FMI 3 Oxygen Sensor Bank A Sensor 2 Heater Voltage Above Normal or Shorted High SPN 66021 FMI 5 Oxygen Sensor Bank A Sensor 2 Heater Current Below Normal or Open Circuit SPN 66021 FMI 8 Oxygen Sensor Bank A Sensor 2 Heater Abnormal Frequency or Pulse Width SPN 66022 FMI 3 Oxygen Sensor Bank B Sensor 2 Heater Voltage Above Normal or Shorted Hig...

Page 57: ...er 2 Voltage Above Normal or Shorted High SPN 66041 FMI 5 OEM Output Driver 2 Current Below Normal or Open Circuit SPN 66042 FMI 3 OEM Output Driver 3 Voltage Above Normal or Shorted High SPN 66042 FMI 5 OEM Output Driver 3 Current Below Normal or Open Circuit SPN 66043 FMI 3 OEM Output Driver 4 Voltage Above Normal or Shorted High SPN 66043 FMI 5 OEM Output Driver 4 Current Below Normal or Open C...

Page 58: ...engine is done with vacuum rather than by pressure If there is a leak present in the plumbing of the closed coolant system the applied vacuum will not pull the coolant into the engine Use the detailed instructions that came with the fill kit for the filling and purging of the coolant system Failure to fill the engine properly with a coolant air evacuation kit may void all warranty Below is a list ...

Page 59: ...3 Shasta Lake Redding Boat Works 530 275 1495 Yuba City Jet stream Concepts 530 674 0655 Johnson Bait and Marine 530 674 1912 Idaho Boise Whitewater Marine 208 377 5110 Lewiston Riverview Marina Custom Weld 800 859 0356 Michigan Marne Camp Cruise 616 677 1274 Montana Billings Jim and Tracy s Alignment 406 259 8496 Butte Rocky Mt RV 406 494 2555 Helena One Way Marine 406 443 7373 Oregon Bend All Se...

Page 60: ...rina 360 835 8553 Woodinville Doug s Boats 800 215 3684 3 Rivers Marine 425 415 1575 British Columbia Abbotsford BC River City Marine 604 852 8599 Chilliwack BC Cascade Supply Marine 800 663 2269 Ventures River Boats 604 824 1498 Kamloops BC River City Marine 250 828 0858 Prince George BC Cycle North 250 964 9091 Richmond BC California Marine 604 278 1880 Alberta Leduc AB Go RV and Marine 888 349 ...

Page 61: ...TROL 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 TH...

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