Opel Insignia Owners & Service Manuals

Opel Insignia: Heated Oxygen and Oxygen Sensor Caution

CAUTION: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor operation.

Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the inline electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not use cleaning solvents of any type.

Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged..

This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in the obstruction of the air reference and degraded sensor performance.

The following guidelines should be used when servicing the heated oxygen sensor:

  • Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance.
  • Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the sensor and cause performance problems.
  • Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire.
  • Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground contact to the sensor. Removal of the ground wire will cause poor engine performance.
  • Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be repaired using an appropriate crimp and splice seals terminal repair kit. Under no circumstances should repairs be soldered since this could result in the air reference being obstructed.


CAUTION: When replacing the HO2S perform the following:

  • A code clear with a scan tool, regardless of whether or not a DTC is set
  • HO2S heater resistance learn reset with a scan tool, where available

Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S failure.


CAUTION: Always ensure the HVAC module drain tube and heater core tubes are properly installed and secure following a repair. Spillage of coolant can result in interior odors and damage to electronic components. Residual moisture/water or coolant can collect inside the HVAC module. The residual moisture/water or coolant should not contact electronic modules, electrical connections, wiring, cables or carpeting. Use clean and absorbent shop cloths to protect these components while removing and installing the HVAC module drain tube, heater core tubes, or the HVAC module. Moisture/water is a by-product of normal A/C system operation and can result in interior odors or corrosion/damage to electrical components.


CAUTION: The OBD II symbol is used on the circuit diagrams in order to alert the technician that the circuit is essential for proper OBD II emission control circuit operation. Any circuit which fails and causes the malfunction indicator lamp (MIL) to turn ON, or causes emissions-related component damage, is identified as an OBD II circuit.


CAUTION: To avoid paint damage, protect the area surrounding the part which you are removing or installing.


CAUTION: The pipe wrench must be placed at the valve end of the steering gear and positioned up against the inner tie rod housing. Placing the pipe wrench in any other location will cause damage to the steering gear.


CAUTION: Do not start the vehicle with any power steering gear inlet or outlet hoses disconnected. When disconnected, plug or cap all openings of components. Failure to do so could result in contamination or loss of power steering fluid and damage to the system.


CAUTION: When grinding drown a panel, do not grind too deep into the material.

The panel has a thickness of 0.65 mm. If the panel is ground down too deep, it may become too thin and will not be usable.


CAUTION: Contamination of the oxygen sensor can result from the use of an inappropriate RTV sealant (not oxygen sensor safe) or excessive engine coolant or oil consumption. Remove the HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to check for contamination. If contaminated, the portion of the sensor exposed to the exhaust stream will have a white powdery coating. Silicon contamination causes a high but false HO2S signal voltage (rich exhaust indication). The control module will then reduce the amount of fuel delivered to the engine, causing a severe driveability problem. Eliminate the source of contamination before replacing the oxygen sensor.


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