Opel Corsa B 1993–2000 Service and Repair Manual: Exhaust system - inspection, removal and refitting


1. The exhaust system should be examined for leaks, damage and security at the intervals given in Routine Maintenance. To do this, apply the handbrake and allow the engine to idle. Lie down on each side of the car in turn, and check the full length of the exhaust system for leaks while an assistant temporarily places a wad of cloth over the end of the tailpipe. If a leak is evident repairs may be made using a proprietary exhaust repair kit. If the leak is excessive, or damage is evident, the relevant section should be renewed. Check the rubber mountings for condition and security and renew them if necessary.


2. To remove the exhaust system, jack up the front and/or rear of the car and support it securely on axle stands. Alternatively drive the front or rear wheels up on ramps or over a pit.

3. The system is made up of three or four sections. The front and rear sections can be removed independently, but to remove a middle section it will be necessary to remove an adjacent end section also. it is certainly easier to free stubborn joints with the complete system removed from the car.

4. To remove a front or rear section, remove the U-bolt clamps which hold the section together. Unhook the section from its rubber mounting rings, and for the front section unbolt the manifold or downpipe (see illustrations). Free the joints and remove the section concerned. The application of penetrating oil will be of assistance in freeing seized joints. Heat from a blowlamp can also be helpful, but take great care to shield the fuel tank, fuel lines and other vulnerable or inflammable areas.

Fuel and exhaust systems - carburettor models
Exhaust system flexible joint

Fuel and exhaust systems - carburettor models
Exhaust system rubber mounting ring


5. Use a little exhaust jointing compound when assembling joints. Renew clamps, rubber rings, seals and gaskets as a matter of course unless they are in perfect condition (see illustration).

Fuel and exhaust systems - carburettor models
Graphite sealing ring fitted at the flexible joint

6. When refitting the complete exhaust system, position it so that the mountings are evenly loaded before tightening the U-bolt clamps.

    Inlet manifold pre-heater (1.6 litre models with automatic transmission) - general information, removal and refitting
    General information 1. An electric manifold pre-heater is fitted to some 1.6 litre models (fitted with a 16SH engine) with automatic transmission. If it malfunctions, warm-up time will be prolonge ...

    Fuel and exhaust systems - fuel-injected models
    Specifications System type Fuel pump Adjustment data Recommended fuel Torque wrench setting ...

    See also:

    Opel Corsa B 1993–2000 Service and Repair Manual. Front suspension control arm - removal and refitting
    Removal 1. Slacken the front wheel bolts, raise and support the vehicle (see "Jacking and Vehicle Support") and remove the front wheel. 2. When fitted, unbolt the anti-roll bar from the control a ...