AP Exhaust 641577 Catalytic Converter with Integrated Exhaust Manifold - Front

Direct-Fit Catalytic Converter Manifold

AP Exhaust 641577 is a Federal / EPA direct-fit catalytic converter with integrated exhaust manifold built for OE-style fitment and emissions performance. It is engineered for the 2013-2016 Hyundai Santa Fe Sport and 2014-2015 Kia Sorento applications listed below, with stainless steel construction and precise OE dimensions.

AP Exhaust uses advanced manufacturing methods and substrate chemistry to support efficient converter loading, consistent fitment, and controlled production quality. The result is a direct replacement for select Hyundai Santa Fe Sport and Kia Sorento front manifold applications, including vehicles with Federal and California emissions configurations where permitted.

Key Features

• Part number: 641577
• Part type: catalytic converter with integrated exhaust manifold
• Federal / EPA direct-fit manifold design
• Stainless steel body material
• 7-bolt welded inlet and 2-bolt welded outlet
• 2 O2 sensor ports
• Overall length: 14 inches
• Includes inlet and outlet hardware as listed in the product data

Fitment Details

• Fits 2013-2016 Hyundai Santa Fe Sport, N/A, Direct Fit; Federal and California Emissions. Not For Sale or Use on vehicles licensed in the state of CA, CO, ME & NY. Restrictions may apply in other states. Check with your state authority for details.
• Fits 2013-2016 Hyundai Santa Fe Sport, Front, Direct Fit; Manifold Unit; Federal and California Emissions. Not For Sale or Use on vehicles licensed in the state of CA, CO, ME & NY. Restrictions may apply in other states. Check with your state authority for details.
• Fits 2014-2015 Kia Sorento, N/A, Direct Fit; Federal and California Emissions. Not For Sale or Use on vehicles licensed in the state of CA, CO, ME & NY. Restrictions may apply in other states. Check with your state authority for details.
• Fits 2014-2015 Kia Sorento, Front, Direct Fit; Manifold Unit; Federal and California Emissions. Not For Sale or Use on vehicles licensed in the state of CA, CO, ME & NY. Restrictions may apply in other states. Check with your state authority for details.
• Fits 2014 Hyundai Santa Fe Sport, N/A, Direct Fit; Federal and California Emissions. Not For Sale or Use on vehicles licensed in the state of CA, CO, ME & NY. Restrictions may apply in other states. Check with your state authority for details.

What This Part Helps Address

• Cracked or leaking exhaust manifold housing
• Restricted catalytic converter flow
• Failed emissions inspection related to converter efficiency
• Exhaust noise from manifold or flange leakage
• Check engine light concerns tied to O2 sensor or catalyst performance

Installation Notes and Tips

Verify engine configuration, emissions type, and sensor locations before installation. This unit uses welded inlet and outlet connections and includes 2 O2 sensor ports, so confirm the vehicle’s exhaust layout and sensor routing match the listed application. For fitment-based searches, this is a direct-fit catalytic converter manifold for 2013-2016 Hyundai Santa Fe Sport and 2014-2015 Kia Sorento front applications.

This part cross-references Hyundai/Kia OE numbers 28510-2G445 and 285102G455 for the same application.

Quality Assurance

AP Exhaust builds this converter manifold to OE dimensions using automated manufacturing processes and spinner welding equipment to support consistent fitment and production accuracy. The ARISTO substrate chemistry is used to improve converter loading efficiency while helping maintain competitive cost and emissions performance.