Opel Insignia: Repair Instructions

Park Brake Calibration

The park brakes do not require calibration often. Park brake calibration may be required after certain service procedures are performed. Some of these procedures are as follows:

• Park brake actuator replacement.
• Rear brake pad replacement.
• Rear brake rotor replacement.
• Rear brake caliper replacement.

The park brake calibration procedure can be completed using the following steps:

1. Block the drive wheels.

2. Install a scan tool to the vehicle.

3. Turn the ignition switch to the ON/RUN position with the engine OFF.

4. Select Configuration/Reset Functions from the electronic brake control module menu.

5. If available, perform the parking brake calibration procedure.

6. If park brake calibration is not available, proceed back and select Control Functions.

7. Perform the Rear Brake Caliper Piston Extend function.

8. Apply and release the park brakes using the park brake switch to ensure that the system is functioning.

PARKING BRAKE ACTUATOR SWITCH REPLACEMENT

Preliminary Procedure

Front Floor Console Trim Plate Replacement

1. Parking Brake Actuator Switch

PARKING BRAKE ACTUATOR REPLACEMENT (GNC)

Removal Procedure

WARNING: Brake Fluid Irritant Warning.

CAUTION: Brake Fluid Effects on Paint and Electrical Components Caution.

1. Set the park brake in Service Mode.

Manual Method

1. Change the transmission gear to neutral or park position.
2. Press and hold the push button start switch for 10 seconds, with the brake pedal not applied.

   This will place the vehicle in Service Mode (Ignition ON with the engine OFF).

3. Press brake pedal several times until brake booster vacuum is empty.
4. Press the brake pedal and press the park brake switch until the orange park brake lamp begins to flash. By keeping the brake pedal applied, release and re-press the park brake switch for approximately 5 seconds.
5. Release the brake pedal. The orange park brake lamp extinguishes for a moment after which the rear brake calipers are retracting.

Scan Tool Method (only use if manual method fails)

1. Install the scan tool to the vehicle and perform the rear brake caliper piston retract.

2. Raise and support the vehicle.

3. Remove the tire and wheel assembly.

4. Rear Brake Caliper - Remove.

5.

Parking Brake Actuator Bolt(1) - Remove[2x].

6.

Parking Brake Actuator(1) - Remove.

7.

Seal Ring(1)@Rear Brake Caliper - Remove and DISCARD.

Installation Procedure

1.

NOTE: The parking brake actuator mounting surfaces of the brake caliper must be clean and free of corrosion and debris.

Seal Ring(1)@Rear Brake Caliper - Install NEW.

2.

Parking Brake Actuator(1) - Install.

3.

CAUTION: Fastener Caution

Parking Brake Actuator Bolt(1) - Install and tighten12 N.m (106 lb in)[2x].

4. Rear Brake Caliper - Install.

5. Bleed the brake system.

6. Install the tire and wheel assembly.

7. Reset the park brake system from Service Mode.

Manual Method

1. Change the transmission gear to neutral or park position.
2. Press and hold the push button start switch for 10 seconds, with the brake pedal not applied.

   This will place the vehicle in Service Mode (Ignition ON with the engine OFF).

3. Press the brake pedal and pull the park brake switch until the orange park brake lamp extinguishes and the rear brake calipers are extending.
4. Release the brake pedal.

Scan Tool Method (only use if manual method fails)

1. Install the scan tool to the vehicle and perform the rear brake caliper piston extend.

Parking Brake Actuator Replacement (GNQ)

Removal Procedure

WARNING: Brake Dust Warning

1. Set the park brake in Service Mode.

Manual Method

1. Change the transmission gear to neutral or park position.
2. Press and hold the push button start switch for 10 seconds, with the brake pedal not applied.

   This will place the vehicle in Service Mode (Ignition ON with the engine OFF).

3. Press brake pedal several times until brake booster vacuum is empty.
4. Press the brake pedal and press the park brake switch until the orange park brake lamp begins to flash. By keeping the brake pedal applied, release and re-press the park brake switch for approximately 5 seconds.
5. Release the brake pedal. The orange park brake lamp extinguishes for a moment after which the rear brake calipers are retracting.

Scan Tool Method (only use if manual method fails)

1. Install the scan tool to the vehicle and perform the rear brake caliper piston retract.

2. Raise and support the vehicle.

3. Remove the tire and wheel assembly.

4.

Rear Parking Brake Actuator Electrical Connector (1) - Disconnect.

5.

Rear Parking Brake Actuator Harness Retainer (1) - Release.

6.

Rear Parking Brake Actuator Bolt (1) - Remove[2x].

7.

Wire Bracket (1) - Remove.

8.

Rear Parking Brake Actuator(1) - Remove.

9.

Rear Parking Brake ActuatorSeal(1) - Remove and DISCARD.

Installation Procedure

1.

Rear Parking Brake ActuatorSeal(1) - Install NEW.

2.

Rear Parking Brake Actuator(1) - Install.

3.

Wire Bracket (1) - Install.

4.

CAUTION: Fastener Caution

Rear Parking Brake Actuator Bolt (1) - Install and tighten 12 N.m (106 lb in)[2x].

5.

Rear Parking Brake Actuator Harness Retainer (1) - Secure.

6.

Rear Parking Brake Actuator Electrical Connector (1) - Connect.

7. Install the tire and wheel assembly.

8. Reset the park brake system from Service Mode.

Manual Method

1. Change the transmission gear to neutral or park position.
2. Press and hold the push button start switch for 10 seconds, with the brake pedal not applied.

   This will place the vehicle in Service Mode (Ignition ON with the engine OFF).

3. Press the brake pedal and pull the park brake switch until the orange park brake lamp extinguishes and the rear brake calipers are extending.
4. Release the brake pedal.

Scan Tool Method (only use if manual method fails)

1. Install the scan tool to the vehicle and perform the rear brake caliper piston extend.

PARKING BRAKE SERVICE MODE SELECTION

Rear Parking Brake Actuator Release - Service Mode

Prior to any rear disc brake or parking brake service, the parking brake actuator must be placed in Service Mode.

1. Install a scan tool to the vehicle.
2. Turn the ignition ON with the engine OFF.
3. On the scan tool menu, select Electronic Brake Control Module.
4. Select Control Functions.

NOTE: Do NOT apply any brake pedal pressure during this step.

5. Select Rear Brake Caliper Piston Retract.
6. After the repair is complete, calibrate the park brake. Park Brake Calibration

Rear Parking Brake Actuator Release - Manual Release

In the event the rear parking brake actuator fails or there is a loss of electrical power, the parking brake may be released manually.

1. Remove the rear parking brake actuator. Rear Parking Brake Actuator Replacement.
2. Insert an appropriate hex tool past the splines of the parking brake actuator piston apply spindle in the brake caliper.
3. Rotate the parking brake actuator piston apply spindle clockwise to release the parking brake.
4. After the repair is complete, calibrate the park brake.

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