Applications

This Toyota 2KD-FTV engine overhaul gasket kit 04111-0L080 directly replaces factory sealing components in the following configurations-9-2:

Cross-reference chassis codes for fitment:

• Hilux: AN10, AN120, KUN2_4, N140 (2002–2008, 2KD-FTV)

• Fortuner: AN60 (2004–2008, 2KD-FTV)

• Innova / Kijang: AN40 (2004–2008, 2KD-FTV)

• Hiace: H200 (2004–2008, 2KD-FTV)

The 2KD-FTV engine production began in 2001 and continues today, but 04111-0L080 is specifically the overhaul kit for the 2002–2008 generation vehicles with the standard 2KD-FTV (not the later high-output/common rail 3 variants). For parts distributors serving Toyota light‑commercial fleets, this single SKU covers the majority of 2KD-powered Hilux, Fortuner, Innova, and Hiace vehicles from the mid‑2000s.

Why This Gasket Kit Matters for 2KD-FTV Engines

The Toyota 2KD-FTV is a robust workhorse, but it has well‑documented vulnerabilities that make a quality gasket kit essential during any top‑end service-24:

• Piston cracking (pre-2011): Early 2KD-FTV engines are prone to aluminum piston cracking. If the engine has been overhauled with new pistons, the head gasket and full seal set must be replaced to factory spec. This kit provides the correct MLS head gasket thickness matched to piston protrusion-.

• Injector failure: The 2KD’s Denso common rail injectors are sensitive to fuel quality and may fail around 100,000 km. When replacing injectors, the intake manifold and injector seals must be renewed—both included in this kit.

• Coking and oil consumption: The 2KD-FTV is prone to oil burning due to piston ring coking and carbon buildup in the EGR system. A full top‑end service using this gasket kit, combined with decarbonization, restores compression and oil control.

• Timing belt service: The 2KD uses a rubber timing belt (not a chain). With a recommended replacement interval of 150,000 km, the timing cover gaskets and front seals must be replaced whenever the belt is serviced—all included here.

Kit Contents

04111-0L080 is a comprehensive full gasket set, containing every sealing component for a complete engine overhaul or top-end rebuild. For the 2KD-FTV, this includes-:

Note on cylinder head gasket thickness: Toyota 2KD-FTV engines use different head gasket thicknesses depending on piston protrusion, indicated by notch codes (A, B, C, D, etc.) stamped on the cylinder head. This full kit includes a standard thickness gasket. If your specific engine requires a different thickness (notch code B, C, or D), confirm before ordering or purchase the head gasket separately-.

What is NOT included: Cylinder head bolts. The 2KD-FTV uses torque‑to‑yield (stretch) bolts that must be replaced with new units whenever the cylinder head is removed. Order cylinder head bolts separately (Toyota OE numbers vary by year; confirm your application).

Features & Benefits

Multi‑Layer Steel (MLS) Cylinder Head Gasket
The 2KD-FTV uses a steel-laminate MLS head gasket with an elastomer coating on the sealing beads. Unlike older composition gaskets, MLS design maintains consistent clamping force through thousands of thermal cycles, even under the 17.4–18.5:1 compression ratio and peak cylinder pressures exceeding 1,600 psi. The stainless steel fire rings around each 92.0 mm bore resist corrosion and maintain spring force at exhaust gas temperatures up to 800°C-24.

Complete Single‑Kit Solution
This overhaul set replaces the need to source individual gaskets from multiple suppliers. For a workshop performing a full engine rebuild, one part number covers the cylinder head, valve cover, intake/exhaust manifolds, timing cover, oil pan, valve stem seals, and all associated O-rings. This reduces ordering complexity and ensures no small gasket is overlooked during reassembly.

16-Valve DOHC Compatibility
The 2KD-FTV’s DOHC valvetrain uses solid valve lifters (no hydraulic lifters) and 16 valves. The kit includes all 8 valve stem seals (2 per cylinder) made from Viton/fluoroelastomer, rated for continuous 200°C service. Correct valve stem sealing prevents oil consumption past the valve guides—a known cause of blue smoke on high‑mileage 2KD engines-24.

Heat‑Resistant Elastomer Seals
All O-rings and rubber gaskets in this kit are manufactured from heat‑resistant materials (NBR, EPDM, or FKM depending on application). The injector seals resist swelling from diesel fuel exposure, and the camshaft seals maintain flexibility through winter cold starts and summer heat soak.

IATF 16949 / ISO 9001 Certified Manufacturing
Aftermarket versions from established suppliers are manufactured under IATF 16949 and ISO 9001 certified quality management systems—the automotive industry’s highest standard for component production. Material certificates and dimensional inspection records are retained per batch.

Extensive OE Cross‑Reference for Easy Matching
The kit accepts multiple OE numbers: 04111-0L080 (primary), 04111-30030, 04111-30571, 04111-30420. The partial head set is 04112-0L080. When a customer searches by any of these numbers—whether in OE parts look-ups or aftermarket cross‑reference databases—this listing provides the correct fitment-.

Quality Control & Verification

Each batch of the Toyota 2KD-FTV engine overhaul gasket kit 04111-0L080 undergoes the following verifications:

A certificate of conformance (COC) with batch test data is available for wholesale orders.

Installation & Maintenance Recommendations

⚠️ IMPORTANT: The 2KD-FTV uses torque‑to‑yield (stretch) cylinder head bolts. These are single-use fasteners. If your engine has the original head bolts, they must be replaced with new bolts (ordered separately) whenever the cylinder head is removed. Reusing old bolts risks uneven clamping, head gasket failure, and cylinder head warping.

Why a quality gasket kit is critical for 2KD-FTV longevity:

The 2KD-FTV engine is durable but has two recurring issues that directly involve gaskets-:

1. Piston cracking (pre-2011): This is a known metallurgical issue, not a gasket failure. However, when replacing cracked pistons (common during an overhaul), the head gasket must be renewed. The correct MLS head gasket thickness must be selected based on the new piston protrusion (notch code).

2. Oil consumption from coking: The 2KD-FTV is prone to piston ring coking and carbon buildup in the EGR system, leading to oil burning. A full top‑end service using this gasket kit—including new valve stem seals, intake/exhaust gaskets, and EGR gasket—restores compression and oil control.

Recommended replacement indicators for 2KD-FTV engines:

Procedural notes when using this gasket kit:

When performing any engine overhaul that includes head gasket replacement on a 2KD-FTV engine, the following should be observed:

• Always replace cylinder head bolts with new genuine‑spec bolts. Torque‑to‑yield bolts cannot be reused. Consult the Toyota Repair Manual for the correct tightening sequence (typical: staged torques of 30 Nm → 70 Nm → 90 Nm followed by 90° angle turns).

• Confirm head gasket thickness selection. Toyota 2KD-FTV engines use piston protrusion to determine the required head gasket thickness (A/B/C/D notch codes). This kit includes a standard thickness. If piston replacement has been performed, or if the original engine had a non‑standard notch code, verify the required thickness before reassembly.

• Check cylinder head and block surfaces for warpage using a precision straight edge. Warpage beyond spec (typically >0.05 mm) will cause gasket failure regardless of gasket quality.

• Clean and chase all bolt holes in the cylinder block to remove debris and old thread sealant. Compressed air should be used to clear each hole before bolt installation.

• Replace the timing belt during head gasket service. The 2KD-FTV uses a rubber timing belt (not a chain). The recommended replacement interval is 150,000 km. Since the front timing cover is removed for head gasket access, the belt and tensioner should be replaced at the same time. This kit includes the timing cover gaskets for this purpose.

• Replace the water pump while the timing belt is accessible. Although not included in this gasket kit, a new water pump is recommended when replacing the timing belt.

• Use only Toyota Super Long Life Coolant (SLLC, pink) or equivalent ethylene‑glycol coolant mixed 50/50 with distilled water.

• Consider professional installation. Head gasket replacement on the 2KD-FTV is a complex procedure requiring specialised tools (torque‑angle gauge, precision straight edge) and access to the Toyota Repair Manual. Time for a professional workshop is typically 6–8 hours for a full head gasket service.

Maintenance schedule for 2KD-FTV engines:

• Replace timing belt every 150,000 km — includes timing cover gasket replacement (gaskets included in this kit)

• Replace engine coolant every 5 years or 100,000 km — degraded coolant accelerates head gasket corrosion

• Replace EGR gasket whenever the EGR valve or cooler is removed for carbon cleaning — included in this kit

• Replace valve cover gasket at every valve clearance inspection (every 40,000 km recommended)

• Consider preventive head gasket replacement at 300,000–400,000 km on high‑cycle vehicles (delivery vans, construction trucks)

Packaging & Supply

• Individual packaging: Sealed in anti‑static VCI bag, foam‑lined carton

• Carton dimensions: Approximately 55 × 40 × 5 cm (depending on supplier)

• Net weight: Approximately 2.5–3.5 kg (depending on kit completeness)

• Gross weight (with packaging): 3.0–4.0 kg

• Master carton: 20 units per export carton (palletizable)

• Lead time: 3–7 working days for stock orders; 15–25 days for production orders above 100 pieces

• Minimum order quantity: 1 piece (sample order available)

• Shipping methods: FedEx, UPS, DHL for samples; sea freight (LCL/FCL) from Shanghai, Ningbo, Guangzhou ports

• H/S Code: 8484.90

For workshops planning a full engine rebuild, the supplier also stocks matching 2KD-FTV cylinder head bolts (11101-30040 family) , timing belt kits (including Dayco/Gates belts and tensioners), water pumps, and piston ring sets for complete engine overhaul. Contact the sales team with your forecasted monthly volume and destination port for a tiered price list.

Quick Summary

The Toyota 2KD-FTV engine overhaul gasket kit 04111-0L080 is a complete OE‑spec sealing solution for 2.5L D-4D turbo-diesel engines in Hilux (2002-2008), Fortuner (2004-2008), Innova (2004-2008), Hiace (2004-2008), and Kijang vehicles. The kit includes the MLS steel-laminate cylinder head gasket, valve stem seals, intake/exhaust manifold gaskets, oil pan and timing cover gaskets, and all associated seals. It is the professional choice for head gasket replacement, valve service, or full engine overhaul. IATF 16949 certified with multiple OE cross‑reference numbers (04111-0L080 / 04111-30030 / 04111-30571 / 04111-30420).

Order a sample unit today — restore your 2KD-FTV engine to factory sealing with a single part number.