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

Inspection

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.

Removal

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.

Exhaust system flexible joint

Exhaust system rubber mounting ring

Refitting

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).

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.