Exhaust manifold catalytic converter replacement on a 2004 Nissan Frontier 3.3L 2WD can follow a confirmed cracked assembly, exhaust leak, damaged internal core or failed catalyst test. P0420 (Bank 1) and P0430 (Bank 2) are relevant catalyst-efficiency codes, but neither code alone proves that a converter needs replacement. Diagnose the affected bank and repair engine faults before fitting new parts.
This guide covers the naturally aspirated 3.3L V6. The selected product is a left-and-right pair of manifold/converter assemblies. The joint references below cover 2004 Nissan Frontier 3.3L 2WD. Establish safe access to each assembly on the actual truck before loosening fasteners; the separate fitment table lists the broader product applications.
Advanced DIY; both exhaust banks and old manifold fasteners
Allow 6–10 hours for both sides after diagnosis; estimate
Approximately $350–$600 for the pair and routine materials; estimate
Use eye protection, suitable gloves and a hard, level work surface. Chock the wheels and use rated stands at approved support points before reaching underneath. Never rely on a hydraulic jack alone. Support disconnected exhaust sections and keep penetrant away from flames. Broken manifold studs, damaged head threads, seized sensors or uncertain support require professional help.
Featured left-and-right manifold/converter kit
A-Premium APCCT158 — ASIN B0CRHNJPT8 is the selected two-piece kit: one left/driver-side and one right/passenger-side assembly. Each includes an integrated exhaust manifold and catalytic converter. The advertised construction uses a six-bolt head flange, three-bolt outlet, one oxygen-sensor port per assembly and ceramic substrate.
The kit cross-references include 140029S210, 140029S200, 674-816, 674-818, 641244 and 641243. Gaskets and bolts are advertised, but inspect the package for the exact seals, fasteners and sensor-port fittings your vehicle needs. Oxygen sensors, downstream exhaust sections and complete replacement hardware are not assured inclusions.
View the Left and Right Manifold Converter Kit
Vehicle compatibility and exclusions
| Vehicle | Catalog years | Required engine | Check before ordering |
|---|---|---|---|
| Nissan Frontier | 2002–2004 | 3.3L V6, naturally aspirated | Federal-emissions application; confirm VIN, emissions label, both flange layouts and sensor fittings. |
| Nissan Xterra | 2002–2004 | 3.3L V6, naturally aspirated | Product fitment only; access and fasteners must match the exact vehicle. |
| Excluded applications | Not covered by this kit | Supercharged 3.3L, 2.4L four-cylinder, later 4.0L V6 | Do not substitute by model name, similar appearance or a single cross-reference number. |
A-Premium’s APCCT158 catalog identifies the pair and naturally aspirated restriction. Check the selected Left and Right option when ordering. A two-piece package does not establish that both existing converters have failed; replace only where diagnosis and the applicable installation requirements justify it.
Federal emissions and state restrictions
The seller lists this as a federal-emissions product and excludes California, Colorado, New York and Maine. Match the underhood certification label and engine family/test group to the exact converter application and local rules. A matching flange or delivery address does not establish legal eligibility.
California requires the applicable CARB authorization. Colorado and New York have covered-vehicle requirements; Maine distinguishes originally CARB/50-state vehicles from federal-only vehicles. Consult the primary state guidance below and respect this seller’s restrictions. Retain the invoice and replacement-need records, and check any remaining original emissions-warranty coverage.
Diagnose the correct bank before disassembly
Record stored and pending codes, freeze-frame data and monitor status before clearing anything. On this VG33E engine, Bank 1 is the right/passenger side, containing cylinders 1, 3 and 5; Bank 2 is the left/driver side, containing cylinders 2, 4 and 6. Left and right refer to vehicle sides, not your view facing the grille.
| Finding | Useful next check | Why it matters |
|---|---|---|
| P0420 or P0430 | Related engine codes, exhaust leaks, fuel control and oxygen-sensor behavior on the indicated bank | Efficiency monitoring can be affected by other faults; a code is not a parts order. |
| Ticking or exhaust smell | Cracked manifold, loose shield, broken stud and head/outlet gasket joints | A sealing or hardware problem may need repair even when the catalyst core is sound. |
| Rattle or loss of power | Loose external hardware, damaged core and exhaust restriction | Locate the cause; an efficiency fault and a flow restriction are different conditions. |
| Misfire, rich operation or fluid consumption | Ignition, fueling and engine mechanical condition | Unburned fuel, oil or coolant can damage the replacement converters. |
Nissan’s diagnostic chart addresses the manifold catalyst on the indicated bank. Resolve front-sensor response codes P0133/P0153 and related engine faults before condemning it. A basic reader documents codes; professional testing may still be needed. Do not use sensor spacers, remove the catalyst core or alter software to hide a fault. Stop driving for severe misfire, a glowing converter, major power loss or exhaust entering the cab.
Tools, parts and supplies
The products below are equipment examples. Confirm actual fastener size, access, drive fit and safe support height. Use the correct torque scale, protect sensor leads and obtain every required new gasket before dismantling either bank.
| Tool or Supply | Exact Product | Product Link | Purpose and Selection Check |
|---|---|---|---|
| Metric sockets, ratchets and extensions | DEWALT DWMT73803 168-piece mechanics tool set | View metric sockets, ratchets and extensions | Six-point metric sockets, three ratchet drives, extensions and universal joints serve manifold, shield and flange hardware. Match actual fasteners and clearance; additional socket sizes may be needed. |
| Breaker bar — useful | TEKTON SBH00118 3/8-inch-drive 18-inch breaker bar | View breaker bar | An 18-inch, 3/8-inch-drive bar provides controlled leverage on cooled exhaust hardware. Use fully seated sockets; stop for twisting studs or rounding nuts. Reserve torque wrenches for tightening. |
| Small torque wrench | LEXIVON LX-181 1/4-inch-drive inch-pound torque wrench | View small torque wrench | The 1/4-inch LX-181 covers 20–200 in-lb / 2.26–22.6 N·m for heat-shield hardware and low-torque fasteners. Select the specified setting and distinguish inch-pounds from foot-pounds. |
| Manifold and sensor torque wrench | LEXIVON LX-182 3/8-inch-drive torque wrench | View manifold and sensor torque wrench | The 3/8-inch LX-182 covers 13.6–108.5 N·m, including manifold nuts, sensors and a 78 N·m adapter if transferred. Match socket drive and account for offset-tool geometry. |
| Upstream oxygen-sensor tools | OEMTOOLS 27110 three-piece oxygen-sensor socket set | View upstream oxygen-sensor tools | Three 22 mm/7/8-inch tools include a straight 3/8-inch-drive slotted socket. Check seating and clearance, disconnect sensor leads before turning, and use a matching drive. |
| Vehicle floor jack | BIG RED / Torin T83006 hydraulic trolley jack | View vehicle floor jack | Lifting capacity is 3 tons without the adapter, 2.5 tons with it. Check loaded vehicle, approved lifting points and reachable stand height. Use stands before working underneath. |
| Support stands — matched pair | BIG RED / Torin T46002A double-locking jack stands, one pair | View support stands | The T46002A pair supports 6 tons at 15-3/8–23-13/16 inches. Match approved support points and reachable height; engage both locks. The capacity applies to the pair. |
| Wheel chocks — pair | MAXXHAUL 70472 solid-rubber wheel chocks, two-pack | View wheel chocks | Two solid-rubber chocks measure 8 × 4 × 6 inches. Secure the wheels remaining on the ground before lifting, following vehicle and support-equipment instructions. |
| Penetrating oil — useful | B’laster 16-PB penetrating catalyst, 11-ounce can | View penetrating oil | An 11-ounce aerosol helps loosen cooled external nuts and studs. Ventilate, avoid ignition sources, protect sensor tips and converter interiors, and remove excess before assembly. |
| Eye protection | 3M 91252H1-DC-10 chemical-splash and impact goggles | View eye protection | Clear splash and impact goggles protect against falling rust and chemical splashes. Adjust the strap for a secure fit and confirm the selected retail quantity. |
| OBD-II reader — optional | ANCEL AD310 OBD-II engine/emissions code reader | View obd-ii reader | Records emissions codes, supported live data, freeze-frame and readiness. Preserve diagnostic evidence before clearing codes. Basic scanner readings alone do not establish a failed converter. |
| Chemical-handling gloves | Ansell Sol-Vex 37-185/9 chemical-resistant nitrile gloves, Large, one pair | View chemical-handling gloves | Large nitrile gauntlets have 22-mil palms and 18-inch coverage. Select the correct size and chemical compatibility. Cool the exhaust fully; these gloves are not heat protection. |
| Shop towels | Scott Shop Towels Original — confirm selected pack quantity | View shop towels | Use for external cleanup and excess penetrant. Confirm selected pack quantity. Keep towels and fibers away from open ports, sensor tips and converter internals. |
| Plastic gasket scraper — if needed | Lisle 81200 three-piece plastic chisel scraper set | View plastic gasket scraper | Three plastic blades, 3/4, 1 and 1-1/2 inches wide, lift remaining gasket residue. Work gently without gouging mating faces or letting debris enter open ports. |
| Sensor-bung thread-cleaning lubricant — conditional | Permatex 81343 / 133AR Anti-Seize Lubricant, 1-ounce tube | View sensor-bung thread-cleaning lubricant | For prescribed sensor-bung thread cleaning only. This 1-ounce 133AR lubricant meets MIL-A-907E. Keep it off sensing tips and remove cleaning residue as directed before installation. |
| Sensor-bung thread chaser — conditional | Lisle 12230 M18×1.5 oxygen-sensor thread chaser | View sensor-bung thread chaser | Cleans M18×1.5 sensor-bung threads using a 3/8-inch drive or 3/4-inch hex. Confirm thread size and need before use; avoid cutting sound new threads. |
| New manifold-to-head gaskets — both banks | Left- and right-bank gaskets matching the vehicle and converter kit | Confirm exact fit and supplied kit contents | Match each gasket to its cylinder head and converter flange. Check both banks and kit contents before disassembly; replace removed gaskets as Nissan directs. |
| New outlet seals or gaskets — both banks | Correct seals for both converter-to-front-tube joints | Match both outlet joints and verify supplied seals | Confirm the sealing shape and dimensions at both front-tube connections. Obtain missing seals before starting and follow Nissan’s replacement instructions for each disturbed joint. |
| Replacement exhaust hardware — conditional | Correct replacement bolts, studs, nuts and sealing hardware | Match the vehicle, bank and converter instructions | Replace unusable hardware with the correct thread, grade, length and geometry. Check both banks and supplied parts; do not substitute universal hardware or add unspecified coatings. |
| EGR union and sensor-adapter tools — conditional | Correctly sized flare/crowfoot wrench and adapter socket as needed | Measure actual hex sizes and check access before purchase | Select tools that fully engage the actual fitting and match the torque-wrench drive. Confirm access before disturbing either connection; account for a crowfoot’s offset. |
DIY versus professional repair costs
Planning estimates in US dollars for both eligible federal manifold/converter assemblies. These are not live checkout or shop quotes. Taxes, shipping, separate diagnosis, broken-stud extraction and cylinder-head repair are excluded.
| Cost category | DIY estimate | Professional estimate |
|---|---|---|
| Left-and-right converter kit | $300–$450 | $500–$1,000 for eligible aftermarket parts; other emissions applications may cost more |
| New seals, routine materials and minor hardware | $50–$150 | $60–$140 |
| Tools | $0 if suitable tools are owned; allow $500–$900 for a full equipment purchase | Normally part of labor overhead |
| Labor | Allow 6–10 hours of your time | Illustrative 5–8 hours at $120–$180/hour: $600–$1,440 |
| Example total | $350–$600 before tools | $1,160–$2,580 before separate diagnosis or major extraction |
Ask whether the quote includes both banks, sensor transfer, all disturbed gaskets and final leak/monitor checks. A one-bank repair should be quoted separately. Corroded manifold studs can make labor less predictable than the price of the kit.
2004 Nissan Frontier 3.3L 2WD repair sequence
Service-planning scope: The component sequence and specifications below apply to the 2004 Frontier 2WD, naturally aspirated VG33E 3.3L. A technician should assess access to both banks, connected pipes and surrounding components before disassembly, including any additional removal needed for the actual truck.
| Bank on a U.S. left-hand-drive truck | Manifold/catalyst monitor |
|---|---|
| Bank 1: right/passenger side | P0420 |
| Bank 2: left/driver side | P0430 |
Bank orientation follows Nissan’s cylinder layout and sensor-location diagrams.
1. Prepare the truck and identify connections
Let the engine and exhaust cool completely. Switch the ignition off, work on a level surface and chock both sides of the wheels remaining on the ground. Raise at the prescribed points and support the frame on safety stands; never work under a jack alone. Use GI-37 for the lifting arrangement. Identify each bank’s sensor harness, heat shield, outlet flange and EGR connection before loosening anything.
2. Free the exhaust and electrical connections
Label and unplug the upstream oxygen-sensor connectors before turning either sensor. If front exhaust tubes will move, release their rear-sensor wiring so the leads cannot stretch. Support the downstream exhaust, separate the manifold outlet flanges and retain the pipes without loading the remaining joints. Discard every opened exhaust gasket. Remove the manifold heat shields as access permits; EX-5 identifies the 2WD front tubes and rear sensors.
3. Handle the sensors and EGR connection carefully
Use the specified 22 mm front-sensor wrench, Nissan KV10117100/J36471-A or a suitable equivalent. Protect sensor tips, connectors and leads. Nissan requires replacement if a sensor falls more than 0.5 m onto a hard surface. Before installing a new sensor into reused threaded components, follow the thread-cleaning instructions using the correct cleaner and approved lubricant; do not cut new threads in an undamaged new part.
Free the EGR connection without bending the tube. EM-80 specifies 39–49 N·m at the EGR tube-to-valve union. That value is specific to the depicted union; establish the correct treatment and specification before disturbing any other EGR fitting.
4. Remove each supported manifold assembly
Support the assembly and loosen its six cylinder-head fasteners in the reverse of the tightening order below, matching EM-108. Remove the assembly and discard its head-flange gasket. Inspect sealing faces, studs and head threads. Broken studs, damaged threads or obstructed removal require the appropriate additional repair/access procedure; do not force the assembly past pipes or wiring.
5. Install new gaskets and tighten by bank
Fit the correct new manifold-to-head gasket and position each assembly. Start all six nuts correctly. Tighten 1 through 6 to 28.5–33.3 N·m using the bank-specific EM-118 drawing. The numbers below follow the drawing’s outward manifold-side view: on the right-bank drawing, engine front is to the right; on the left-bank drawing, engine front is to the left. Match that orientation before assigning numbers.
| Position row in each Nissan drawing | Tightening numbers from drawing left to right |
|---|---|
| Upper row | 6, 1, 4 |
| Lower row | 3, 2, 5 |
This table lists row positions rather than a scaled hole template. The tightening order is 1 → 2 → 3 → 4 → 5 → 6. If disturbed, the head studs and manifold-outlet studs are 12.7–16.7 N·m; install head studs with the short threaded end toward the head, as shown in EM-85. Use correct hardware and its specified thread condition.
6. Reassemble the remaining joints
Install the upstream sensors at 40–60 N·m. The separate original sensor adapter, where fitted and disturbed, is 78 N·m; this is not the sensor torque or a specification for a welded bung. Reinstall the heat-shield fasteners at 9.22–10.8 N·m. Reconnect the EGR tube at its correct joint specification and restore sensor routing/connectors.
Install new outlet gaskets and tighten the manifold-to-front-tube nuts to 43–50 N·m. If additional 2WD downstream flanges were opened, their depicted nuts are 43–55 N·m; the depicted exhaust support/mounting fasteners are 13–16 N·m. Rear sensors, if removed, are 40–60 N·m. Align the system without stressing brackets or insulators, then restore any access components and lower safely.
7. Check leakage and catalyst operation
Run the engine outdoors or with exhaust extraction. Check opened joints for leaks and the system for unusual noise; let it cool before corrections. Verify the original complaint and the applicable bank’s catalyst monitor. EC-896–900 requires checking exhaust damage/leaks, intake leaks, ignition and injector faults before condemning a manifold catalyst. Clearing codes alone does not verify the repair.
Common mistakes
- Ordering the supercharged or later 4.0L application for a naturally aspirated 3.3L truck.
- Confusing vehicle left/right with the view from the front bumper.
- Replacing both banks solely because the product is sold as a pair.
- Forcing an assembly into alignment with its fasteners or reusing a crushed gasket.
- Using an oxygen-sensor spacer to conceal a catalyst-efficiency fault.
- Twisting sensor wiring, leaving a shield off or ignoring a returning engine fault.
Frequently asked questions
Does the kit include both exhaust manifolds?
The selected APCCT158 kit is advertised as two integrated manifold/converter assemblies, one for each side. Inspect all seals, hardware and sensor fittings before starting.
Will it fit a supercharged 3.3L Frontier or Xterra?
This kit’s supported application is naturally aspirated only. The same displacement does not establish fitment for the supercharged engine.
Do P0420 and P0430 mean both converters are bad?
No. Identify the affected bank and test related engine, exhaust and sensor faults before replacing any converter.
Can I reuse functioning oxygen sensors?
Only if they are undamaged, correct for the application and removed without damaging their threads or leads. Follow the sensor manufacturer’s installation instructions.
Is a dark warning light enough to confirm the repair?
No. Check for leaks, verify the original complaint and confirm that the applicable catalyst monitor runs and passes without returning faults.
Sources and further reading
- A-Premium APCCT158 — fitment and paired assembly
- A-Premium APCCT158 — construction, quantity and exclusions
- Nissan 2004 Frontier factory manual — EM-76/77 tools; EM-80 EGR union; EM-85 VG33E manifold components and torques; EM-108/118 sequences; EM-144 cylinder numbering
- Nissan 2004 Frontier factory manual — EX-2/3 sensor/exhaust precautions; EX-5 VG33E 2WD exhaust joints and torques
- Nissan 2004 Frontier factory manual — EC-663/664 sensor/bank locations; EC-896–900 P0420/P0430 diagnosis
- Nissan 2004 Frontier factory manual — GI-37 lifting points and safety stands
- EPA aftermarket converter guidance
- California Air Resources Board — aftermarket converters
- Colorado Regulation20
- New York DEC converter program
- Maine DEP aftermarket-converter FAQ