Opel Insignia Owners & Service Manuals

Opel Insignia: Repair Instructions

Brake Pedal Position Sensor Calibration

Calibration Criteria

NOTE: Do not apply the brake pedal during the brake pedal position sensor calibration procedure. Any movement of the brake pedal during this procedure will cause the calibration procedure to fail. If this occurs, the brake pedal position sensor calibration must be repeated.

Brake pedal position sensor calibration must be performed after the brake pedal position sensor, body control module (BCM), engine control module (ECM), or hybrid powertrain control module have been serviced. The calibration procedure will set the brake pedal position sensor home value. This value is used by the BCM and ECM/HPCM to determine the action of the driver applying the brake system and to provide this information to the vehicle subsystems via serial data.

Calibration Procedure

1. Apply the parking brake.

2. Ignition ON, engine OFF, place the transmission in the PARK position for automatic transmission or NEUTRAL position for manual transmission.

3. Install a scan tool.

4. Clear all DTCs before proceeding.

5. Navigate to the Configuration/Reset Functions menu of the BCM.

6. Select the Brake Pedal Position Sensor Learn procedure and follow the directions displayed on the screen.

7. Navigate to the Configuration/Reset Functions menu of the ECM/HPCM.

8. Select the Learn Functions menu.

9. Select the Brake Pedal Position Sensor Learn procedure and follow the directions displayed on the screen.

BRAKE PEDAL POSITION SENSOR REPLACEMENT

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  1. Brake Pedal Position Sensor Bolt
    CAUTION: Fastener Caution
    Tighten 2.5 N.m (22 lb in)
  2. Brake Pedal Position Sensor
    Procedure
    1. Disconnect the electrical connector.
    2. Unlock the retaining tabs.
    3. Brake Pedal Position Sensor Calibration

HEADLAMP SWITCH REPLACEMENT

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Preliminary Procedure

Instrument Panel Fuse Block Access Hole Cover Replacement

  1. Headlamp Switch
    Procedure
    Unlock the retaining tabs.

HAZARD WARNING SWITCH REPLACEMENT

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Preliminary Procedure

Radio Control Assembly Replacement (IOB) Radio Control Assembly Replacement (IO5, IO6).

  1. Hazard Warning Switch
    Procedure
    Unlock the retaining tabs.

CENTER READING LAMP REPLACEMENT (WITHOUT SUNROOF)

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  1. Center Reading Lamp
    Procedure
    1. Unlock the retaining tabs.
    2. Use a flat bladed plastic trim tool.
    3. Disconnect the electrical connector.

FRONT SIDE DOOR INSIDE HANDLE ILLUMINATION LAMP REPLACEMENT

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Preliminary Procedure

Front Side Door Trim Replacement.

  1. Front Side Door Inside Handle Illumination Lamp
    Procedure
    Unlock the retaining tabs.

REAR SIDE DOOR INSIDE HANDLE ILLUMINATION LAMP REPLACEMENT

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Preliminary Procedure

Rear Side Door Trim Replacement.

  1. Rear Side Door Inside Handle Illumination Lamp
    Procedure
    Unlock the retaining tabs.

FRONT FLOOR FLOOD LAMP REPLACEMENT

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Preliminary Procedure

Front Side Door Sill Garnish Molding Replacement.

  1. Front Floor Flood Lamp
    Procedure
    Unlock the retaining tabs.

INSTRUMENT PANEL COMPARTMENT LAMP REPLACEMENT

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Preliminary Procedure

Instrument Panel Compartment Replacement.

  1. Instrument Panel Compartment Lamp
    Procedure
    Unlock the retaining tabs.

ROOF RAIL REAR SEAT POSITION READING AND COURTESY LAMP REPLACEMENT

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Preliminary Procedure

Roof Rail Assist Handle Replacement.

  1. Roof Rail Rear Seat Position Reading and Courtesy Lamp
    Procedure
    1. Use a suitable tool. Unlock the retaining tabs.
    2. Disconnect the electrical connector.

REAR SEAT POSITION CENTER READING LAMP REPLACEMENT (WITH SUNROOF)

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  1. Rear Seat Position Center Reading Lamp Retainer [2x]
  2. Rear Seat Position Center Reading Lamp
    Procedure
    1. Unlock the retaining tabs.
    2. Use a flat bladed plastic trim tool.
    3. Disconnect the electrical connector.

SUNSHADE ILLUMINATED MIRROR LAMP BULB REPLACEMENT

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Preliminary Procedure

Sunshade Illuminated Mirror Lamp Lens Replacement.

  1. Sunshade Illuminated Mirror Lamp Bulb

SUNSHADE ILLUMINATED MIRROR LAMP LENS REPLACEMENT

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  1. Sunshade Illuminated Mirror Lamp Lens
    Procedure
    Use a flat bladed plastic tool to remove.

FRONT SIDE DOOR MAP POCKET ILLUMINATION LAMP REPLACEMENT

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Preliminary Procedure

Front Side Door Trim Replacement.

  1. Front Side Door Map Pocket Illumination Lamp
    Procedure
    Unlock the retaining tabs.

HEADLAMP REPLACEMENT

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Preliminary Procedure

Front Bumper Fascia Headlamp Opening Bracket Replacement.

  1. Headlamp Bolt [3x]
    CAUTION: Fastener Caution
    Tighten 2.5 N.m (22 lb in)
  2. Headlamp
    Procedure
    1. Disconnect the electrical connector.
    2. Transfer components as necessary.
    3. After installation, program the headlamp control module.
    4. After installation, aim the headlamp if necessary.

Headlamp Bulb Replacement - Left Side (High Beam)

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Preliminary Procedure

Windshield Washer Solvent Container Filler Tube Replacement.

  1. Headlamp Bulb Access Cover
    WARNING: Halogen Bulb Warning.
    Procedure
    Rotate the cover counterclockwise to remove.
  2. Headlamp Bulb - High Beam
    Procedure
    1. Disconnect the electrical connector.
    2. Unlock the retaining tabs.

HEADLAMP BULB REPLACEMENT - LEFT SIDE (LOW BEAM)

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  1. Headlamp Bulb Access Cover
    WARNING: Halogen Bulb Warning.
    Procedure
    Rotate the cover counterclockwise to remove.
  2. Headlamp Bulb - Low Beam
    Procedure
    1. Release the bulb retainer spring
    2. Disconnect the electrical connectors.

HEADLAMP BULB REPLACEMENT - RIGHT SIDE (HIGH BEAM)

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  1. Headlamp Bulb Access Cover
    WARNING: Halogen Bulb Warning.
    Procedure
    Rotate the cover counterclockwise to remove.
  2. Headlamp Bulb - High Beam
    Procedure
    1. Disconnect the electrical connector.
    2. Unlock the retaining tabs.

HEADLAMP BULB REPLACEMENT - RIGHT SIDE (LOW BEAM)

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  1. Headlamp Bulb Access Cover
    WARNING: Halogen Bulb Warning.
    Procedure
    Rotate the cover counterclockwise to remove.
  2. Headlamp Bulb - Low Beam
    Procedure
    1. Release the bulb retainer spring.
    2. Disconnect the electrical connectors.

HEADLAMP BRACKET REPLACEMENT

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Preliminary Procedure

Front Bumper Fascia Replacement.

  1. Headlamp Bolt
    CAUTION: Fastener Caution
    Tighten 2.5 N.m (22 lb in)
  2. Headlamp Bracket Bolt
    Tighten 2.5 N.m (22 lb in)
  3. Headlamp Bracket

Headlamp Aiming

General

Directive 76/756 EEC and ECE-Regulation 48 cover checking and aiming of headlamps on vehicle.

Correct aiming of headlamps of vehicles should enable optimal road illumination by the low beam, with minimal glare to oncoming traffic. For this purpose the inclination of the light beam in relation to the road surface and the angle of the beam to the vertical longitudinal plane running through the vehicle centre must comply with the requirements laid down in the ECE regulation and EEC directive.

Glaring of the low beam is considered eliminated if the intensity of the illumination at a distance of 25 m (82 ft) from each individual headlamp on the plane perpendicular to the road and at the height of the headlamp as well as above, is not greater than 1 lux. This requirement is generally satisfied if the headlamp aiming is carried out according to these aiming guidelines.

For the nondazzling high beam (Intelilux) special attention must be turned to the correct lateral alignment of the headlamps (low beam).

If a non-railed adjustment device will be used, the lateral orientation of the adjustment device has to be checked separately in front of each single headlamp.

The measurement of adjustment for the basic headlamp aiming is displayed in % on the headlamp housing.

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Example: Label for a headlamp inclination of 1.0% for the low beam on the headlamp.

Reference 1.0 percent corresponds to the adjustment dimension of the headlamp with reference to the inclination of the light beam. The inclination at a distance of 10 m (33 ft) from vehicle headlamp is therefore 10 cm (4 in). The inclination of the low beam headlamp is indicated by its light/dark boundary (cut-off line).

Depending on the specific inner design of the headlamps, the movement of the lightbeam on the measurement screen is not exactly vertical or horizontal during the aiming on the aiming screws. This is caused by the technical solution of the suspension of the reflectors in the headlamp housing. After aiming of one axis the aiming of the other axis should be rechecked. For instance the vertical aiming could be changed a bit after the aiming of the horizontal axis. Therefore the vertical axis must be checked and if necessary aimed again after the aiming of the horizontal axis.

If a headlamp shows a significant deviation from the correct aiming for both horizontal and vertical direction the aiming operation must be performed step by step for the two directions. This means that in such a case the aiming of horizontal and vertical direction must be done alternately in small steps. Not more than one turn of an aiming screw shall be performed at once. After one turn change to the other aiming screw. Repeat this procedure until the headlamp is correctly aimed.

Headlamp Beam Setter / Inspection Station

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Abbreviations used:

  1. Horizontal distance between headlamp centres
  2. Central marking
  3. Test surface

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  1. Test surface
  2. Road surface
  3. Break point (kink of cut-off line)

e = Aiming dimension in cm, e = H - h (aiming dimension, low beam headlamps usually at 1.0 percent,

e = 10 cm (4 in), front fog lamps 2.0 percent, e = 20 cm (8 in), high beam headlamps (if separately amiable) at 0 percent, e = 0 cm (0 in).

H = Height of centre of headlamp over road surface

h = Height of light/dark boundary line (cut-off line) of low beam above road surface

The headlamp aiming is performed according to the specifications, as shown in the illustrations, using an adjuster. When using a headlamp adjuster, set up the height and position of the adjuster according to the instructions in the operation manual. Ensure that the vehicle tire surface that is in contact with the road and the surface for setting up the adjuster are at the same level and parallel with each another.

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X = Center of adjuster lens (see arrow mark on adjuster housing) must be aligned on the same level as the low beam headlamp and must be parallel to the ground.

1 = Use marking of the control mirror (1) to align the adjuster system in the correct angle to the vehicle, based on the information shown in the owner operating instructions.

The distance between the adjuster lens and the headlamp must be max. 0, 9 meters (refer to operation instructions of the adjuster system) The surface on which the measuring instrument (adjuster system) and the vehicle stand must be flat. See following table.

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Vehicle tires must have specified air pressure. Blackened bulbs must be replaced before adjusting.

The adjustment is performed at vehicle curb weight plus one person or 75 kg (165 lb) on the driver's seat. (Curb weight = weight of vehicle ready for use with 90% filled fuel tank plus the weight of all equipment carried during use, e.g. spare wheel, tools, jack, first aid kit, emergency warning triangle, etc.).

Light Pattern / Scheme of Headlamps

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  1. Kink of cut-off line for the left/right setting
  2. Horizontal area of the cut-off line for up/down setting

1 and 2 = Depending on the headlamp setup the outer sections will be straight or increasing.

Headlamp Aiming

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The headlamp switch must be turned on manual low beam if equipped, the manual headlamp range adjustment has to be in the zero position.

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Halogen Headlamp

  1. Aiming screw for vertical adjustment
  2. Aiming screw for horizontal adjustment

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LED-Matrix Headlamp

  1. Aiming screw for vertical adjustment
  2. Aiming screw for horizontal adjustment

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NOTE: Guide and adjust the headlamps always from below to the horizontal area of the separation line

For the vertical adjustment (adjustment of the height), the separation line has to be on the left side of the adjustment cross parallel to the horizontal adjustment line (1).

NOTE: At first perform the vertical (1) and then the lateral adjustment. Check the vertical adjustment again after the lateral adjustment.

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To assure the correct lateral adjustment the horizontal increase (inflection point) must lay on the vertical separation line A (0 degree).

This is elementary for a flawless LED Matrix functionality.

NOTE: This description is valid for right hand traffic. For left hand traffic the light pattern of left and right side is mirrored.

The reference run must be performed for the headlamps after headlamp aiming. The reference run result automatic when ignition is on and the headlamp switch be turned on manual low beam. During the reference run check for enough clearance between the projection-type module and the reflector and that the module bezel is free from scratches. In case of a touch condition between the projection-type module and bezel during the reference run or visible scratches on the bezel the headlamp aiming must be checked again. Conditions like these occur if the aiming differs extremely from the set position.

FRONT SUSPENSION AUTOMATIC FORWARD LIGHTING POSITION SENSOR REPLACEMENT

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Preliminary Procedure

Tire and Wheel Removal and Installation.

  1. Retainer
  2. Front Suspension Automatic Forward Lighting Position Sensor Nut
    CAUTION: Fastener Caution
    Tighten 9 N.m (80 lb in)
  3. Front Suspension Automatic Forward Lighting Position Sensor
    Procedure
    1. Disconnect the electrical connector.
    2. Unlock the retaining tabs.
    3. Run all necessary programming and setup procedures.

REAR SUSPENSION AUTOMATIC FORWARD LIGHTING LEVELING POSITION SENSOR REPLACEMENT

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Preliminary Procedure

Tire and Wheel Removal and Installation.

  1. Rear Suspension Automatic Forward Lighting Leveling Position Sensor Nut
    CAUTION: Fastener Caution
    Tighten 9 N.m (80 lb in)
  2. Rear Suspension Automatic Forward Lighting Leveling Position Sensor
    Procedure
    1. Disconnect the electrical connector.
    2. Unlock the retaining tabs.
    3. Run all necessary programming and setup procedures.

Suspension Position Sensor Calibration

Calibration Criteria

NOTE: Remove any excess weight and do not sit in the vehicle during the headlamp leveling sensor learn procedure. Any additional weight will cause the calibration of the front and rear suspension position sensors to be inaccurate and affect the operation of the headlamp leveling system.

The headlamp leveling sensor learn procedure must be performed after a suspension position sensor has been removed/reinstalled/replaced, or if the headlamp leveling control module has been serviced. The learn procedure will set the front and rear suspension position sensors home value. This value is used by the headlamp leveling control module to determine the movement of the front and rear suspension systems. The headlamp leveling control module compares the information from both suspension position sensors and adjusts the headlamp leveling as needed.

Calibration Procedure

  1. Ignition ON/vehicle in Service Mode.
  2. Install a scan tool.
  3. Navigate to the Configuration/Reset Functions menu of the Headlamp Control Module.
  4. Select Configuration/Reset Functions.
  5. Select Headlamp Leveling Sensor Learn procedure and follow the directions displayed on the screen.

HEADLAMP LED DRIVER MODULE REPLACEMENT

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Preliminary Procedure

Headlamp Replacement.

  1. Headlamp LED Driver Module Screw [3x]
    CAUTION: Fastener Caution
    Tighten 2.5 N.m (22 lb in)
  2. Headlamp LED Driver Module
    Procedure
    1. Disconnect the electrical connector.
    2. After installation, aim the headlamps.

HEADLAMP CONTROL MODULE REPLACEMENT (T4L WITH T95 AND UVG)

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  1. Headlamp Control Module Nut [2x]
    CAUTION: Fastener Caution
    Tighten 9 N.m (80 lb in)
  2. Headlamp Control Module
    Procedure
    1. Disconnect the electrical connector.
    2. Perform the necessary programming and setup procedure: Control Module References

HEADLAMP CONTROL MODULE REPLACEMENT (T4L WITHOUT T95 AND UVG)

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Preliminary Procedure

Headlamp Replacement.

  1. Headlamp LED Driver Module Bolt [3x]
    CAUTION: Fastener Caution
    Tighten 2.5 N.m (22 lb in)
  2. Headlamp Control Module
    Procedure
    1. Disconnect the electrical connectors.
    2. Run all necessary programming and setup procedure.

FRONT FOG LAMP REPLACEMENT

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Preliminary Procedure

Front Fog Lamp Bezel Replacement (Base) Front Fog Lamp Bezel Replacement (YWC).

  1. Front Fog Lamp Bolt [3x]
    CAUTION: Fastener Caution
    Tighten 2.5 N.m (22 lb in)
  2. Front Fog Lamp
    Procedure
    1. Disconnect the electrical connector.
    2. Replace bulbs as necessary.

FRONT FOG LAMP BRACKET REPLACEMENT

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Preliminary Procedures

1. Front Bumper Fascia Replacement.

2. Front Fog Lamp Replacement.

  1. Front Fog Lamp Bracket
    Procedure
    Unlock the retaining tabs in direction of the arrow.

FRONT FOG LAMP AND FRONT OBJECT SENSOR WIRING HARNESS REPLACEMENT

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Preliminary Procedures

1. Front Bumper Fascia Replacement.

2. Front Bumper Fascia Energy Absorber Replacement.

  1. Front Fog Lamp and Front Object Sensor Wiring Harness Retainer [6x]
  2. Front Fog Lamp and Front Object Sensor Wiring Harness
    Procedure
    1. Disconnect the electrical connectors.
    2. Unlock the retaining tabs.

FRONT SIDE MARKER LAMP REPLACEMENT

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Preliminary Procedure

Front Wheelhouse Liner Replacement (LGX) Front Wheelhouse Liner Replacement (LTG).

  1. Front Side Marker Lamp
    Procedure
    1. Disconnect the electrical connector.
    2. Squeeze the front side marker lamp retainer, pull outward and down to remove front side marker lamp from the fascia.
    3. Transfer components as necessary.

FRONT SIDE TURN SIGNAL LAMP REPLACEMENT

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  1. Front Side Turn Signal Lamp
    Procedure
    1. Use a flat bladed plastic tool to remove.
    2. Unlock the retaining tabs in direction of the arrow.
    3. Disconnect the electrical connector.
    4. Replace bulbs as necessary.

HIGH MOUNT STOP LAMP REPLACEMENT (WAGON)

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Preliminary Procedure

Rear End Spoiler Replacement (5-Door Wagon 35).

  1. High Mount Stop Lamp Bolt [2x]
    CAUTION: Fastener Caution
    Tighten 2.5 N.m (22 lb in)
  2. High Mount Stop Lamp
    Procedure
    Disconnect the electrical connector.

HIGH MOUNT STOP LAMP REPLACEMENT (HATCHBACK)

Removal Procedure

1.

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Liftgate Upper Side Trim Finish Panel (2) - Remove.

2.

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High Mount Stop Lamp Nut (1) - Remove [4x].

3. Disconnect the electrical connector.

4. Release the retaining tab.

5. Apply a double layer of masking tape around the perimeter of the painted surfaces.

6.

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Using a flat-bladed trim tool, apply appropriate force between the taped surface and high mount stop lamp (1) to release.

7.

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High Mount Stop Lamp (1) - Remove.

Installation Procedure

1.

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High Mount Stop Lamp (1) - Install.

2. Remove the double layer of masking tape around the perimeter of the painted surfaces.

3. Connect the electrical connector.

4.

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CAUTION: Refer to Fastener Caution.

High Mount Stop Lamp Nut (1) - Install and tighten [4x] 2.5 N.m (22 lb in).

5.

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Liftgate Upper Side Trim Finish Panel (2) - Install.

REAR BODY STRUCTURE STOP LAMP REPLACEMENT (5-DOOR HATCHBACK 68)

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Preliminary Procedure

Open the rear compartment side trim panel service flap.

  1. Rear Body Structure Stop Lamp Nut [2x]
    CAUTION: Fastener Caution
    Tighten 2.5 N.m (22 lb in)
  2. Rear Body Structure Stop Lamp
    Procedure
    1. Unlock the retaining tabs.
    2. Disconnect the electrical connector.
    3. Replace bulbs as necessary.

REAR BODY STRUCTURE STOP LAMP REPLACEMENT (5-DOOR WAGON 35)

Removal Procedure

1. Liftgate - Open.

2.

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Rear Body Structure Stop Lamp Cap (1) - Remove [2x].

3. Unlock the retaining tabs.

4.

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Rear Body Structure Stop Lamp Bolt (1) - Remove [2x].

5. Rear Body Structure Stop Lamp (2) - Remove.

6. Unlock the retaining tabs.

7. Disconnect the electrical connector.

8. Replace bulbs as necessary.

Installation Procedure

1.

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CAUTION: Fastener Caution.

Rear Body Structure Stop Lamp (2) - Install.

2. Connect the electrical connector.

3. Rear Body Structure Stop Lamp Bolt (1) - Install and tighten [2x] 2.5 N.m (22 lb in).

4.

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Rear Body Structure Stop Lamp Cap (1) - Install [2x].

5. Liftgate - Close.

REAR LICENSE PLATE LAMP REPLACEMENT

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  1. Rear License Plate Lamp
    Procedure
    1. Unlock the retaining tabs.
    2. Disconnect the electrical connector.
    3. Replace bulbs as necessary.

TAIL LAMP REPLACEMENT (5-DOOR HATCHBACK 68)

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  1. Liftgate Lower Trim Finish Panel Service Flap
    Procedure
    Unlock the retaining tabs.
  2. Tail Lamp Nut
    CAUTION: Fastener Caution
    Tighten 2.5 N.m (22 lb in)
  3. Tail Lamp
    Procedure
    1. Unlock the retaining tabs.
    2. Disconnect the electrical connector.
    3. Replace bulbs as necessary.

TAIL LAMP REPLACEMENT (5-DOOR WAGON 35)

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  1. Liftgate Lower Trim Finish Panel Service Flap
    Procedure
    Unlock the retaining tabs.
  2. Tail Lamp Nut
    CAUTION: Fastener Caution
    Tighten 2.5 N.m (22 lb in)
  3. Tail Lamp
    Procedure
    1. Unlock the retaining tabs.
    2. Disconnect the electrical connector.
    3. Replace bulbs as necessary.

REAR CLOSURE HANDS FREE LAMP REPLACEMENT (WITHOUT GS BUMPER)

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Preliminary Procedure

Rear Bumper Valance Panel Replacement (Base).

  1. Rear Closure Hands Free Lamp
    Procedure
    1. Disconnect the electrical connector.
    2. Unlock the retaining tabs.

REAR CLOSURE HANDS FREE LAMP REPLACEMENT (WITH GS BUMPER)

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Preliminary Procedure

Rear Bumper Valance Panel Replacement (GS).

  1. Rear Closure Hands Free Lamp
    Procedure
    1. Disconnect the electrical connector.
    2. Unlock the retaining tabs.

REAR COMPARTMENT COURTESY LAMP REPLACEMENT (5-DOOR HATCHBACK 68)

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  1. Rear Compartment Courtesy Lamp
    Procedure
    1. Unlock the retaining tabs.
    2. Disconnect the electrical connector.
    3. Replace bulbs as necessary.

REAR COMPARTMENT COURTESY LAMP REPLACEMENT (5-DOOR WAGON 35)

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  1. Rear Compartment Courtesy Lamp
    Procedure
    1. Unlock the retaining tabs.
    2. Disconnect the electrical connector.
    3. Replace bulbs as necessary.

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