Corsa Exhaust Install

A view of the stock exhaust tips from the rear of the car. Pretty rusty after all these years.

The new exhaust system all laid out and ready to be installed. Test ALL slip fit connections before you proceed any further. They usually need some convincing to fit correctly after shipping.

These are some views of the stock catback from under the rear of the car. To the left, you can see one of the stock hangers (which gets reused in the Corsa design) and on the right you can see the clamp that holds the over the axle pipe to the muffler itself.

Start by disconnecting the rear muffler and tailpipes assembly from the over the axle pipe. They will surely be frozen on by many years of rust, so have plenty of PB Blaster and a breaker bar handy. Next, disconnect the exhaust from the stock catalytic converter at the 2 bolt ball and socket flange (93-95 only) and try to loosen it as much as possible.

Next, using a saw, make a cut somewhere over the axle, to allow the intermediate pipe to be removed without dropping the rear axle. You can remove the g-load brace (black stamped metal brace) if it will help you maneuver it out of the car.

Here is the comparison of the diameter of the stock pipes versus the Corsa pipes. Quite an increase in diameter, as well as much better looking tips.

The Corsa system laid out next to the stock exhaust.

The next step is to install the Corsa pipes in place of the stock ones, reusing all of the stock mounting points, as well as using the two mounting 'billets' Corsa provides. While we have no pictures of this step, it is a fairly simple process to slip these billets into the frame in the rear, where the Corsa mounting hangers bolt to. These take two bolts each, and connect to a rubber hanger, and then to the exhaust pipes. Don't forget to slip all the clamps on first, and tighten everything down.

Some pictures of the system completely installed (note: borrowed from my other Corsa page since no pictures were taken).

Check everything, and start it up. The Corsa exhaust should be rather quiet and mild, not much louder than stock, but with a deeper tone. If it is too loud, check for leaks. Here you can see a picture of the finished exhaust system from the rear of the car.