KEM KODIAK MARINE, Installation Instructions Manual

Page 1: ...KODIAK MARINE CERTIFIED SUPERCHARGED 6 2L LSA ERSONAL INJURY KEM EQUIPMENT INC 10800 SW HERMAN RD TUALATIN OR 97062 PH 503 692 5012 FAX 503 692 1098 www kemequipment com KM10929...

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Page 3: ...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...

Page 4: ...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 l...

Page 5: ...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 G...

Page 6: ...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 EN...

Page 7: ...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 in...

Page 8: ...G 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 CHANG...

Page 9: ...spections 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...

Page 10: ...alified 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 vent...

Page 11: ...ilt 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...

Page 12: ...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 repai...

Page 13: ...13 Component Identification...

Page 14: ...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 FIL...

Page 15: ...ll 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 cod...

Page 16: ...ous 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 reen...

Page 17: ...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 operati...

Page 18: ...hecks 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 tempe...

Page 19: ...il 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 whiche...

Page 20: ...ols 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 equiva...

Page 21: ...mage 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 imp...

Page 22: ...e 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 emergenc...

Page 23: ...e 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 inspected routinely f...

Page 24: ...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 changing fuel filters WARNING Fuel is under HIGH pressur...

Page 25: ...non adjustable and has been factory sealed as required by EPA regulations Any attempt to change the fuel pressure settings will void all warranties for this engine Fuel Pressure The fuel pressure is...

Page 26: ...ll 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...

Page 27: ...TION Always use the recommended spark plug for your engine hotter or colder plugs or similar plugs that are not exact equivalents to the recommended plugs can cause permanent engine damage reduce the...

Page 28: ...drained when ambient temperature is below 32 Degrees F Drain crankcase completely Refill with recommended engine oil SAE 10 or equivalent Shut off fuel supply to the engine run engine until completely...

Page 29: ...level Make sure fluids are at the proper level Check for oil coolant and fuel leaks Correct any leaks prior to proceeding further Check charge and fluid level of battery Inspect connections for corro...

Page 30: ...re at the proper levels Check for oil coolant and fuel leaks Correct any leaks prior to proceeding further Check charge and fluid level of battery Inspect connections for corrosion and clean as necess...

Page 31: ...evel of battery Inspect connections for corrosion and clean as necessary Clean crankcase vent system replace PCV valve Check air cleaner Make sure that it is cleaned replaced as necessary Inspect the...

Page 32: ...Severe weather conditions temps below 32 can cause condensation on the inside of the engine Operating conditions load changes Change of periodic servicing Change of grade or purity of fuel Contaminate...

Page 33: ...ns and clean any corrosion Check battery charge Refer to Pre Operational checklist for further checks Engine Will Crank Intermittently Having to turn the key to START several times Check the ignition...

Page 34: ...uel 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 Check fuel pr...

Page 35: ...he engine cools Adding coolant 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 Ino...

Page 36: ...CHARGER BELT 12628026 GENERAL ENGINE SPECIFICATIONS Engine 6 2L TYPE V 8 DISPLACEMENT 376 CID VALVE CONFIGURATION OVERHEAD ROLLER ROCKERS VALVE LIFTERS HYDRAULIC ROLLER BORE X STROKE INCHES 103 25 X...

Page 37: ...ation Check serpentine belts X X X Inspect battery for case damage and corroded cables X X Inspect electrical and ignition system X X Replace spark plugs X Replace fuel water separator filter X Inspec...

Page 38: ...on of this warranty exceed one 1 year or 100 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...

Page 39: ...ICAL 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 TECHN...

Page 40: ...c OBD System Check 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 th...

Page 41: ...CM controlled starter relay repair the starting system Attempt to start the engine Verify the engine starts and idles If the engine does not start and idle refer to Engine Cranks But Does Not Run Impo...

Page 42: ...essure 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 M...

Page 43: ...15 Engine Coolant Temperature ECT Sensor Circuit Voltage Data Valid But Above Normal Range Least Severe Level SPN 627 SPN Descriptor SPN 627 FMI 15 System Voltage Data Valid But Above Normal Range Le...

Page 44: ...Circuit SPN 656 FMI 3 Fuel Injector 6 Voltage Above Normal or Shorted High SPN 656 FMI 5 Fuel Injector 6 Current Below Normal or Open Circuit SPN 657 FMI 3 Fuel Injector 7 Voltage Above Normal or Sho...

Page 45: ...6 Current Below Normal or Open Circuit SPN 65547 FMI 4 Ignition Coil 7 Voltage Below Normal or Shorted Low SPN 65547 FMI 5 Ignition Coil 7 Current Below Normal or Open Circuit SPN 65548 FMI 4 Ignitio...

Page 46: ...or Out of Adjustment SPN 65592 FMI 7 Misfire Cylinder 2 Mechanical System Not Responding or Out of Adjustment SPN 65593 FMI 7 Misfire Cylinder 3 Mechanical System Not Responding or Out of Adjustment...

Page 47: ...SPN Descriptors SPN 65615 FMI 7 Electronic Throttle Control ETC Actuation Fault Mechanical System Not Responding or Out of Adjustment SPN 65616 FMI 12 Electronic Throttle Control ETC Process Fault Ba...

Page 48: ...SPN 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 6600...

Page 49: ...ntact Voltage Below Normal or Shorted Low SPN 66017 SPN Descriptors SPN 66017 FMI 4 Fuel Pump Relay 1 Voltage Below Normal or Shorted Low SPN 66017 FMI 5 Fuel Pump Relay 1 Current Below Normal or Open...

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