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Kohler KDI 443 Engine

The Kohler KDI 443 is a 3.6 L 4-cylinder atmo engine rated at 1500 rpm, producing up to 11.5 kW. It powers generator sets from Kohler, including the KDW 1404. It holds 2.5 L (0.7 gal) of oil.

Also known as: KOHLER KDI 443

3.6 L

Displacement

Cylinders

1500 rpm

Rated speed

11 kW

Gross power

On this pageSpecs Generator sets Maintenance FAQ Service intervals Torque & specs Fluids Procedures

Engine specifications

Oil capacity	2.5 L
Displacement	3.6 L
Cylinders	4
Aspiration	Atmo
Rated speed	1500 rpm
Gross power	11 kW

Generator sets powered by this engine

Kohler KDW 1404

How to read your Kohler engine serial & model number →

Common problems

The engine rpms suddenly increase and decrease
Fix: THE ENGINE MUST BE STOPPED IMMEDIATELY
The engine does not start
Cause: Sulphated battery terminals corroded, Battery voltage too low, Low fuel level, Frozen fuel, Clogged fuel filter, Air suction in fuel system, Clogged air filter, Clogged pipes, Open fuse, Intake or exhaust system clogged
Fix: Clean the battery terminals, Recharge the battery or replace it, Refuel, Contact KOHLER authorised workshops, Replace with a new filter, Contact KOHLER authorised workshops, Replace with a new filter, Contact KOHLER authorised workshops, Clean the tank and refuel with quality fuel, Replace the engine oil; if the problem persists, contact KOHLER authorised workshops, Replace with a new fuse; if the problem persists, contact KOHLER authorised workshops
The colour of the exhaust fumes suddenly darkens
Fix: THE ENGINE MUST BE STOPPED IMMEDIATELY
Slow acceleration
Cause: Clogged fuel filter
Fix: Replace the fuel filter
RPM instability at idle speed
Cause: Clogged fuel pipes
Fix: Contact KOHLER authorised workshops
Poor quality fuel
Fix: Clean the tank and refuel with quality fuel
Low idle speed
Cause: Clogged fuel pipes
Fix: Contact KOHLER authorised workshops
Excessive fuel consumption
Cause: High oil sump level
Fix: Replace the engine oil; if the problem persists, contact KOHLER authorised workshops
Engine starts but stops
Cause: Inefficient electrical connections, Sulphated battery terminals, Clogged fuel filter, Clogged fuel pipes
Fix: Clean the electrical contacts; if the problem persists, contact KOHLER authorised workshops, Clean the battery terminals, Replace with a new filter and clean the tank, Contact KOHLER authorised workshops
Engine lost its initial performance
Cause: Clogged air filter, Clogged fuel pipes
Fix: Replace with a new filter, Contact KOHLER authorised workshops
Engine jerking
Cause: Clogged fuel pipes
Fix: Contact KOHLER authorised workshops
Blue smoke
Cause: High oil sump level
Fix: Replace the engine oil; if the problem persists, contact KOHLER authorised workshops
A sudden and unusual noise is heard
Fix: THE ENGINE MUST BE STOPPED IMMEDIATELY

Compiled from service & troubleshooting documentation across every generator set that uses the Kohler KDI 443.

Maintenance schedule

Item	Spec	Capacity	Part #	Interval
Fuel filter			—
Oil filter			—
Belt			—
Coolant			—
Oil			—
Spark plug			—

Pooled from every document that names this exact engine — confirm the interval and part number against your unit's serial number.

Service intervals

Item	Action	Hours	Months	Notes
Engine oil	Change	50 hr		First service — After the first 50 working hours
Oil filter	Replace	50 hr		First service — After the first 50 working hours

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Service specifications

Type	Item	Value	Unit	Condition
Clearance	Camshaft journal to housing clearance A-B	0.035÷0.085 (limit 0.170)	mm
Clearance	Clearance between connecting rod big end and pin D-B	0.021÷0.066 (limit 0.130)	mm	bearings tightened
Clearance	Clearance between main bearings and journals C-A	0.023÷0.078 (limit 0.200)	mm	bearings tightened
Clearance	Connecting rod alignment gap A	0.015 (limit 0.030)	mm
Clearance	Crankshaft axial clearance A	0.130÷0.313 (limit 0.5)	mm	main bearings tightened
Clearance	Oil pump clearance between rotors A	max 0.171 (wear limit 0.250)	mm	delivery test at 3600 rpm, oil temperature 120°C
Gap	Piston ring end gap (1st, 2nd, 3rd ring)	0.25÷0.45 (limit 1.0)	mm	ring placed squarely in unworn part of lower cylinder
Injection timing	Injection advance (current pump/injector unit)	12°÷14°	deg	3000÷3600 rpm
Injection timing	Injection advance (current pump/injector unit)	8°÷10°	deg	1500÷2999 rpm
Injection timing	Static injection advance	11° to 13°	deg	adjustments from 1500/3600 rpm
Other	Cylinder bore	75	mm
Other	Displacement	686 / 1028 / 1372	cm3
Other	Stroke	77.6	mm
Pressure	Injector setting pressure (current pump/injector unit)	140÷155	bar
Pressure	Injector setting pressure (old type)	130÷145	bar
Pressure	Oil pressure	not less than 1	bar	maximum operating temperature 120°C at 900 rpm
Pressure	Oil pressure regulating valve opening pressure	4.5÷5.5	bar
Pressure	Turbocharger boost pressure	0.87-0.91 (655÷685 mm Hg)	bar	full speed, full Nb load
Pressure	Turbocharger waste gate calibration pressure	1.11÷1.19 (830÷890 mm Hg)	bar	actuator terminal pushed forward by A = 1 mm
Resistance	Pre-heating water temperature thermistor (T2)	-30°C=12000; -20°C=7000; 0°C=2800; +20°C=1350; +40°C=750; +60°C=490; +80°C=360; +100°C=300; +120°C=270	ohm
Speed	Idle maximum (standard)	3800	rpm	stabilises at 3600 rpm at setting power
Speed	Idle minimum (standard)	850 to 900	rpm
Temperature	Flywheel ring gear heating temperature	300	°C	hold for 15÷20 minutes
Temperature	Thermostatic valve opening temperature	83÷87	°C
Torque	Alternator 14V 45A/65A nut 1	60	Nm
Torque	Camshaft lift pump drive eccentric screw	80	Nm
Torque	Camshaft timing pulley screw	80	Nm
Torque	Connecting rod big end (aluminium connecting rod)	35	Nm
Torque	Connecting rod big end cap screws (tighten simultaneously)	40	Nm
Torque	Cylinder head tightening (3 phases)	50 Nm, then 90° clockwise, then 90° clockwise	Nm/deg
Torque	Driving pulley central screw 1 (left-handed)	360	Nm
Torque	Exhaust manifold nuts	25	Nm
Torque	Flywheel screws	80	Nm
Torque	Fuel lift pump fastening nuts	24	Nm
Torque	Fuel rail holder screws	4	Nm
Torque	Glow plug	20	Nm
Torque	Hydraulic pump drive pinion 2	45	Nm
Torque	Injection pump control rod screws 1 and 2	1.1	Nm
Torque	Injector spark arrester nuts	20	Nm
Torque	Main bearing cap screws	60	Nm
Torque	Oil drain plug	40	Nm
Torque	Oil pan screws	10	Nm
Torque	Oil pressure switch	25	Nm
Torque	Oil pump fastening screws to crankcase	25	Nm
Torque	Oil pump plate screws	10	Nm
Torque	Piston coolant nozzle joint 4	12	Nm
Torque	Plunger barrel ring nut 9	34	Nm
Torque	Pre-combustion chamber ring nut (1st and 2nd tightening)	100 then 180	Nm
Torque	Pump/injector injector ring nut A	70	Nm
Torque	Return pulley bolt 1	25	Nm
Torque	Ringfeder screws 3 (M16 x 1,5)	360	Nm
Torque	Rocker arm assembly support nuts	40	Nm
Torque	Rocker arm cover screws	9	Nm
Torque	Speed governor three screws	10	Nm
Torque	Terminal 2 / alternator 14V 33A nut 1	35÷45	Nm
Torque	Timing belt cover screws	10	Nm
Torque	Timing belt tensioner nut 3	40	Nm
Torque	Vacuum pump fixing screws 9	15	Nm
Torque	Vacuum pump flange screws 8	10	Nm
Valve clearance	Valve / rocker arm clearance A (intake and exhaust)	0.20	mm	engine cold, piston at TDC compression stroke

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Recommended fluids

Fluid	Grade	Standard	Notes
Coolant	50% AGIP ANTIFREEZE SPEZIAL + 50% water (preferably decalcified)		Capacities without radiator: KDW 702 = 0.90 L; KDW 1003 = 1.30 L; KDW 1404 = 1.75 L. Total refill volume varies with engine and radiator type.
Engine oil	AGIP SINT 2000 5W40 (semi-synthetic base oils also listed: SAE 10W-30, 10W-40, 10W-60, 15W-40, 20W-60; synthetic: SAE 5W-30, 0W-30, 5W-40)	API SJ/CF; ACEA A3-96 B3-96; MIL-L-46152 D/E	In countries where AGIP products are not available use oil API CF/SH for Diesel engines or MIL-L-2104 C/46152 D. If oil of lower quality than prescribed is used, replace every 125 h (standard sump) / 150 h (enhanced sump). Select viscosity by ambient temperature per SAE chart (page 33).
Fuel	Commercial diesel No. 1 or No. 2 low sulfur or ultra low sulfur diesel; ASTM D-975 1D or 2D, EN590 or equivalent	ASTM D-975 1D/2D; EN590; BQ-9000 for biodiesel	Winter fuels: summer up to 0°C, winter up to -10°C, alpine up to -20°C, arctic up to -30°C. Biodiesel with less than 20% methyl ester (B20) suitable; do not use vegetable oil as biofuel. Aviation fuels JP5, JP4, JP8 and JET-A (with 5% oil added).

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Procedures

Camshaft timing - belt tightening and fastening adjustment

Tools: Torque wrench, Nippon Denso tension measuring instrument, Belt preload tool 7107-1460-049

Insert torque wrench in the tool with axis A of the key at 90° to axis B of the tool.
Tighten clockwise at 20 Nm.
Remount the drive pulley.
Maintaining belt tension, tighten nut 3 with another torque wrench at 40 Nm.
Rotate crankshaft a few times and recheck tension.

E.G.R. calibration adjustment

Tools: Vacuum pressure gauge 1 bar (or 1 m mercury column), T-branch

Mount T-branch on vacuum valve - E.G.R. valve connection pipe and connect a 1 bar vacuum gauge.
Adjust accelerator lever position so internal adjusting nut 2 is about 5 mm from the thread end.
Accelerate to 3.600 rpm with valve closed; gauge must read 0.
With brake at N=constant load engine down to 2.800 rpm.
Find the E.G.R. valve closing point (vacuum = zero).
Measure consumption; if less than 18.8 mm3/stroke adjust nut closer to rod 3.
Tighten the adjusting nuts when 18.8 mm3/stroke (about 7 kW) is reached.

Injection pumps delivery balancing adjustment

⚠ Each time a pump/injector is replaced it is necessary to balance the deliveries.

Tools: Instrument 7104-1460-127, Test head B

If balancing error exceeds 2 cm³/min adjust injection pump deliveries.
Loosen screws 1 and 2 that block plate 4 and rod 3.
Move plate 4 rightwards relative to rod 3 to increase delivery.
Moving leftwards decreases delivery; make very small movements.
Tighten screws 1 and 2 at 1.1 Nm.

Setting the idle minimum and maximum (standard) adjustment

Fill engine with oil, fuel and coolant; start and warm up 10 minutes.
Turn screw 1 to adjust idle speed at 850 to 900 rpm; tighten locknut.
Turn screw 2 and regulate idle maximum at 3800 rpm; block locknut.

Static injection advance regulation adjustment

Tools: Dial gauge, Tool 7107-1460-048, Tester and special coupling

Fill the tank and operate the fuel pump.
Set pump/injector delivery control rod at half-stroke.
Bring piston to top dead centre of compression.
Prime the injection pump by turning the advance screw lock nut wrench forth and back.
Operate lever 2 to bring drain valve into contact with piston; reset dial gauge.
Go back ¼ turn anticlockwise, then turn forward slowly until fuel level changes.
Check piston lowering against the conversion table.

Turbocharger waste gate adjustment adjustment

Tools: Pressure gauge 0-2 bar, Dial gauge, Pressure reducer, T-joint

Disconnect waste gate tube from turbocharger compressor side.
Connect a 0-2 bar pressure gauge with T-joint to air network via reducer.
Set network air supply pressure 1.5 to 2 bar.
Make a 1.55 mm hole B in the pressure gauge pipe.
Set dial gauge feeler on terminal 2; feed air until terminal 2 moves A = 1 mm.
Read pressure; must be 830÷890 mm Hg (1.11÷1.19 bar).
If low: unscrew locknut 1, remove split pin 9, disconnect rod 8 and adjust terminal 2.
Keep rod steady and do not allow torsion during rotation.

Valve / rocker arm clearance adjustment adjustment

Tools: Feeler gauge

Perform setting with the engine cold.
Bring each cylinder piston to top dead centre on compression stroke.
Set clearance A at 0.20 mm for both intake and exhaust valves.
Alternatively use clearance check B; in this case the value is 0.15 mm.

Regulations for lifting the engine installation

⚠ The lifting point brackets are designed to lift the engine only, not additional weights.

Tools: Lifting beam, Protective gloves

Disconnect power supply, fuel and coolant supply and all mechanical connections.
Attach engine to a suitable lifting device (lifting beam).
Hook the lifting device in the engine lifting points.
Before lifting check weight is balanced by checking its barycentre.
Close all engine openings, wash outside and dry with compressed air.

Dry type air filter cleaning maintenance

⚠ Never clean the filtering element with highly flammable solvents - danger of explosion.

Tools: Compressed air supply

Blow compressed air crossways over the external part and inside the cartridge.
Do not exceed a pressure of 5 atm.
If necessary knock the front of the cartridge repeatedly against a flat surface.
Never clean the element with highly flammable solvents.

Engine storage (protective treatment) maintenance

Tools: Protective sheet

Pour AGIP RUSTIA C protective oil in the engine housing up to maximum level.
Fill up with fuel containing 10% AGIP RUSTIA NT.
Check coolant up to maximum level.
Start engine and keep at minimum idle for some minutes.
Bring engine to ¾ maximum speed for 5÷10 minutes, then switch off.
Empty the fuel tank completely.
Spray SAE 10W on exhaust and intake manifolds.
Seal exhaust and intake ducts, clean external parts, treat non-painted parts, loosen alternator/fan belt, cover with protective sheet.

Timing belt removal maintenance

⚠ When you remove the distributor belt replace it even if its prescribed operation time has not expired yet.

⚠ Always check that the positive pole of the battery is insulated.

Check that the positive pole of the battery is insulated.
Remove belt tensioner 1.
Remove the timing belt off the timing pulley.

Camshaft timing - belt reassembly repair

Remove toothed belt from its protective wrapping only when mounting it.
Fit belt connections to pulley reference marks.
Insert the belt observing the direction of arrows A (direction of rotation).
Tighten nut 1 by hand until the belt tightener rests on the crankcase surface.
Mount camshaft pulley belt first, then crankshaft pulley.
Do not mount driven belts.

Extracted from the manufacturer documentation linked to this model. Values are copied as printed; confirm against your unit's manual and serial number.

Common questions

What is the oil capacity of the Kohler KDI 443?

The Kohler KDI 443 engine has an oil capacity of 2.5 liters.

What is the displacement of the Kohler KDI 443?

The Kohler KDI 443 has a displacement of 3.6 liters with 4 cylinders.

Which generators use the Kohler KDI 443 engine?

The Kohler KDI 443 powers 1 generator set(s), including Kohler KDW 1404.

What is a common problem with the Kohler KDI 443 engine?

A commonly reported issue on generators using the Kohler KDI 443 is: The engine rpms suddenly increase and decrease. Fix: THE ENGINE MUST BE STOPPED IMMEDIATELY.