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Kodiak 5.7L

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KODIAK MARINE
Marine Operators Manual
2.4L 4.3L 5.7L 6.0L AND 6.2L LS3 ENGINES
KEM EQUIPMENT INC
10800 SW HERMAN RD
TUALATIN, OR. 97062
PHONE (503) 692-5012
FAX (503) 692-1098
KM 10701 REV A
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Kodiak 5.7L Specifications

General IconGeneral
Displacement5.7L
Engine typeV8
Fuel TypeGasoline
Compression Ratio9.6:1
Fuel SystemMulti-port Fuel Injection
ValvetrainOHV

Summary

Introduction to Kodiak Marine Engines

How to Use This Manual

Explains how to navigate and utilize the manual's sections for effective learning and engine familiarization.

Engine Identification and Information

Model and Serial Number Identification

Details the engine identification placard, model, and serial numbers for reference and parts ordering.

Warranty Card Requirements

Outlines the importance of filling and returning the warranty card for coverage and engine identification.

Component Identification Guide

Engine Component Diagrams

Visual guide illustrating the location and names of various engine parts with labels.

Engine Control Locations

Shows general locations of engine controls and their functions via illustrations.

Parts and Service Information

Obtaining Parts and Service

Information on how to acquire replacement parts and access service from authorized dealers.

Service Literature Availability

Guidance on purchasing additional service manuals for Kodiak Marine engines.

Pre-Operational Inspection Procedures

Pre-Start Engine Checks

Essential checks to perform before starting the engine to ensure safe operation.

Fluid and Leak Identification

Procedures for checking engine oil, coolant levels, and identifying leaks.

Battery and Arrester Inspections

Inspecting battery connections for corrosion and spark arrester for obstructions.

Malfunction Indicator Light (MIL) System

Check Engine Light (MIL) Explanation

Details the function of the Check Engine Light and fault code diagnosis.

Check Gauges Light Functionality

Explains the 'Check Gauges' light for non-emissions related issues and safeties.

Starting the Engine Procedures

Pre-Starting Engine Checks

Steps to follow before cranking the engine, including fluid checks and bilge blower use.

Starting Mode and Fuel Injection

Describes how the ECM manages fuel delivery during starting modes.

Cold Engine Start Behavior

Explains the elevated idle speed characteristic of a cold engine start.

Stopping the Engine Procedures

Normal Engine Shutdown

Recommended procedure for idling the engine before shutting it off normally.

Overheating Shutdown and Coolant Check

Steps for stopping an overheating engine and safely checking coolant.

Maintenance Instructions Overview

Initial Start-Up Maintenance

Procedures to follow before initial engine service, referencing the schedule.

Routine Maintenance Points

Key service points for regular engine upkeep and performance.

Maintenance Schedule Reference

Directs users to the maintenance schedule for item checks and replacements.

General Engine Specifications (2.4 L)

2.4 L Engine Specifications

Detailed specifications for the 2.4L engine, including type, displacement, and bore.

2.4 L Quick Reference Chart

Provides a quick chart for 2.4L engine parts like filters, plugs, and oil.

General Engine Specifications (4.3 L)

4.3 L Engine Specifications

Detailed specifications for the 4.3L engine, covering configuration and capacity.

4.3 L Quick Reference Chart

Quick reference chart for 4.3L engine parts, including oil filter and spark plugs.

General Engine Specifications (5.7 L)

5.7 L Engine Specifications

Technical details for the 5.7L engine, including bore, stroke, and fuel type.

5.7 L Quick Reference Chart

Quick reference for 5.7L engine parts like spark arrestor and fuel pressure.

General Engine Specifications (6.0 L)

6.0 L Engine Specifications

Specifications for the 6.0L engine, covering displacement, balance method, and oil capacity.

6.0 L Quick Reference Chart

Quick reference chart for 6.0L engine parts, including spark plugs and serpentine belt.

General Engine Specifications (6.2 L LS3)

6.2 L LS3 Engine Specifications

Specifications for the 6.2L LS3 engine, detailing bore, fuel system, and coolant capacity.

6.2 L LS3 Quick Reference Chart

Quick reference chart for 6.2L LS3 engine parts like spark plugs and engine oil.

Maintenance Schedule Details

General Maintenance Checks and Intervals

Outlines daily and general maintenance tasks with their service intervals.

Engine Coolant Maintenance Procedures

Tasks related to checking and replacing engine coolant and hoses.

Engine Electrical System Maintenance

Maintenance for battery, ignition system, and spark plugs.

Fuel System Maintenance Procedures

Procedures for fuel filter replacement and fuel pressure checks.

Changing Engine Oil and Filter

Engine Oil Level Check Procedure

Instructions on how to check the engine oil level daily before starting.

Adding Engine Oil and Quality

Guidance on adding oil and the importance of using quality lubricating oils.

Recommended Engine Oil Specifications

Specifies recommended oil standards (ILSAC GF-4) and API starburst symbol.

Oil Filter and Flame Arrestor Service

Oil Filter Replacement Procedure

Step-by-step guide for removing and installing a new oil filter.

Flame Arrestor Purpose and Service

Explains the function of the flame arrestor and service frequency.

Cooling System Management

Coolant Type and Mixture Recommendation

Recommends DEX COOL coolant and a 50/50 mixture for GM engines.

Coolant Level Checking Procedure

Instructions for checking the coolant level in the heat exchanger daily.

Heat Exchanger and Serpentine Belt

Heat Exchanger Inspection Points

Details daily checks for the heat exchanger, cap, hoses, and connections.

Serpentine Belt Tension and Condition

Guidance on checking the serpentine belt tensioner and belt condition.

Fuel Injection System Maintenance

Fuel System Filter Maintenance

Emphasizes the importance of timely fuel filter changes to prevent component failure.

Fuel Filter Replacement Safety

Safety precautions for changing fuel filters due to flammable fuel and pressure.

Fuel Filter Function and Schedule

Explains the fuel/water separator filter's role and replacement interval.

Fuel Type and Performance Considerations

Recommended Fuel Octane and Ethanol

Specifies recommended fuel octane and maximum ethanol content for engines.

Power Loss at Higher Elevations

Explains power loss due to altitude and the role of the MAP sensor.

Ignition System Safety and Components

Ignition System Safety Warnings

Warns about high voltage and electrical shock hazards associated with the ignition system.

Recommended Spark Plug Usage

Advises using recommended spark plugs to prevent engine damage.

Troubleshooting Common Engine Issues

Common Engine Operating Problems

Lists common problems like battery connections, fuel quality, and weather conditions.

Importance of Regular Maintenance

Stresses that maintenance prevents most problems and advises dealer consultation.

Troubleshooting Specific Engine Problems

Engine Does Not Crank Diagnosis

Troubleshooting steps for an engine that fails to crank.

Engine Cranks But Does Not Start

Guidance for diagnosing issues when the engine cranks but doesn't start.

Engine Stuttering or Chattering Noise

Steps to diagnose stuttering or chattering noises from the engine.

Troubleshooting Engine Overheating

Engine Runs Hot Diagnosis

Discusses potential causes and checks for an engine running hot.

Causes of Engine Overheating

Lists specific items that can lead to engine overheating.

Emissions Compliance and Engine Use

Emissions Compliance Standards

States the engine is designed to meet CARB and EPA emissions requirements.

Engine Modification Warning

Warns against unauthorized modifications that can cause damage or void warranty.

Engine Storage and Lay-Up Procedures

One Month Storage (Lay-Up)

Instructions for preparing the engine for one month of storage.

Indefinite Period Storage (Lay-Up)

Procedures for storing the engine for an indefinite period.

Periodic Maintenance Inspection Schedule

100, 300, 500, 700, 900 Hour Inspections

Details the maintenance tasks required at specific hour intervals.

400 Hour Inspection Tasks

Outlines the specific maintenance steps for the 400-hour service interval.

Periodic Maintenance Inspection (Continued)

800 Hour Inspection Tasks

Lists the maintenance procedures for the 800-hour service interval.

California Emission Control Warranty

Warranty Rights and Obligations

Explains the owner's rights and responsibilities regarding emission control warranty.

Warranty Coverage Details

Outlines what emission control parts are covered and for how long.

General Emissions Warranty Coverage

Warranty Period Commencement and Duration

Details when the emission warranty period begins and its duration.

Warranty Coverage Conditions and Exclusions

Explains conditions and exclusions for warranty coverage of parts.

Emission-Related Parts Coverage

Covered Emission Control Systems

Lists systems and parts covered under the emission warranty.

Warranty Service Procedures

Guidelines for obtaining warranty service and repairs at a station.

Warranty Exclusions and Limitations

Miscellaneous Covered Items

Lists additional parts and components covered under warranty.

Warranty Exclusions Explained

Details conditions and actions that void the warranty coverage.

Kodiak Marine Engine Warranty Terms

3 Year Limited Warranty Terms

Outlines the terms and duration of the 3-year limited warranty.

Warranty Service Request Process

Steps for requesting warranty service and contacting Kodiak Marine.

Warranty Exclusions and Damage Disclaimers

Specific Warranty Exclusions

Lists specific conditions and components not covered by the warranty.

Disclaimer of Consequential Damages

Limits Kodiak Marine's responsibility for indirect or consequential damages.

On Board Diagnostic (OBD) System

OBD System Safety Warnings

Safety precautions for performing diagnostics on the OBD system.

Electronic Control Precautions

Steps to prevent damage to sensitive electronic components during diagnosis.

Preliminary OBD Diagnosis Steps

Initial checks and verification steps before starting OBD diagnosis.

OBD Diagnostic Procedures

Attempting Engine Start Verification

Verification steps for engine cranking and starting after diagnosis.

SPN Diagnosis Order

Specifies the order in which to diagnose reported SPNs (Stored Parameter Numbers).

Diagnostic Error Codes (SPN 100-174)

SPN 100-174 Error Code Descriptions

Details error codes for Engine Oil Pressure, MAT, MAP, ECT, and Fuel Temperature sensors.

Diagnostic Error Codes (SPN 627-654)

SPN 627-654 Error Code Descriptions

Lists codes for System Voltage, Calibration/Device Faults, CKP Sensor, and Fuel Injectors.

Diagnostic Error Codes (SPN 65541-65610)

SPN 65541-65610 Error Code Descriptions

Covers Ignition Coil, CAN Bus, Oxygen Sensor, and Throttle Position sensor codes.

Diagnostic Error Codes (SPN 65601-65723)

SPN 65601-65723 Error Code Descriptions

Details codes for Throttle/Pedal Position Sensors, ETC, 5V Reference, and CMP sensors.

Diagnostic Error Codes (SPN 66001-66021)

SPN 66001-66021 Error Code Descriptions

Lists codes for Starter Relay, MIL, SVS Lamp, Powertrain Relay, and Oxygen Sensor Heater.

Service Dealer Locations (United States)

US Service Dealers by State

Lists authorized service dealers in Alaska, Arizona, California, and Idaho.

Service Dealer Locations (Continued)

International Service Dealers

Lists authorized service dealers in Oregon, Washington, Canada, and Russia.

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