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
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Preliminary Procedure
Front Floor Console Trim Plate Replacement
- 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
- Change the transmission gear to neutral or park position.
- 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).
- Press brake pedal several times until brake booster vacuum is empty.
- 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.
- 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)
- 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.
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Parking Brake Actuator Bolt(1) - Remove[2x].
6.
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Parking Brake Actuator(1) - Remove.
7.
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Seal Ring(1)@Rear Brake Caliper - Remove and DISCARD.
Installation Procedure
1.
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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.
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Parking Brake Actuator(1) - Install.
3.
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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
- Change the transmission gear to neutral or park position.
- 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).
- Press the brake pedal and pull the park brake switch until the orange
park brake lamp
extinguishes and the rear brake calipers are extending.
- Release the brake pedal.
Scan Tool Method (only use if manual method fails)
- 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
- Change the transmission gear to neutral or park position.
- 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).
- Press brake pedal several times until brake booster vacuum is empty.
- 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.
- 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)
- 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.
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Rear Parking Brake Actuator Electrical Connector (1) - Disconnect.
5.
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Rear Parking Brake Actuator Harness Retainer (1) - Release.
6.
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Rear Parking Brake Actuator Bolt (1) - Remove[2x].
7.
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Wire Bracket (1) - Remove.
8.
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Rear Parking Brake Actuator(1) - Remove.
9.
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Rear Parking Brake ActuatorSeal(1) - Remove and DISCARD.
Installation Procedure
1.
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Rear Parking Brake ActuatorSeal(1) - Install NEW.
2.
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Rear Parking Brake Actuator(1) - Install.
3.
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Wire Bracket (1) - Install.
4.
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CAUTION: Fastener Caution
Rear Parking Brake Actuator Bolt (1) - Install and tighten 12 N.m (106 lb
in)[2x].
5.
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Rear Parking Brake Actuator Harness Retainer (1) - Secure.
6.
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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
- Change the transmission gear to neutral or park position.
- 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).
- Press the brake pedal and pull the park brake switch until the orange
park brake lamp
extinguishes and the rear brake calipers are extending.
- Release the brake pedal.
Scan Tool Method (only use if manual method fails)
- 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.
- Install a scan tool to the vehicle.
- Turn the ignition ON with the engine OFF.
- On the scan tool menu, select Electronic Brake Control Module.
- Select Control Functions.
NOTE: Do NOT apply any brake pedal pressure during this step.
- Select Rear Brake Caliper Piston Retract.
- 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.
- Remove the rear parking brake actuator. Rear Parking Brake Actuator
Replacement.
- Insert an appropriate hex tool past the splines of the parking brake
actuator piston apply spindle in
the brake caliper.
- Rotate the parking brake actuator piston apply spindle clockwise to
release the parking brake.
- After the repair is complete, calibrate the park brake.
READ NEXT:
ELECTRONIC PARKING BRAKE DESCRIPTION
Vehicles with the electric parking brake have a switch in the center console
or on the dash, which takes
the place of the manual parking brake system, the foot pe
Opel Wheel Alignment Specifications
WHEEL ALIGNMENT SPECIFICATIONS
Insignia GNC 225/55 R17
Insignia GNC 245/40 R19
Insignia GNC 245/45 R18
Insignia GNQ 225/55 R17
Insignia GNQ 245/40 R19
Insigni
SPECIFICATIONS
FASTENER SPECIFICATIONS
Reusable Threaded Fastener Tightening Specifications
NOTE:
All fasteners listed in this table can be reused after removal.
SCHEMATIC AND WIRING DIAGRAMS
ELECTRO
SEE MORE:
SPECIFICATIONS
FASTENER SPECIFICATIONS
Single Use Threaded Fastener/Component Tightening Specifications
NOTE:
All fasteners/components listed in this table MUST BE DISCARDED and replaced
with NEW after removal.
Reusable Threaded Fastener Tightening Specifications
NOTE:
All fasteners listed in this
Windshield Wiper and Washer Switch Replacement
Preliminary Procedures
1. Steering Column Lower Trim Cover Replacement.
2. Reposition the steering column upper trim cover as necessary.
Windshield Wiper and Washer Switch
Procedure
Disconnect the electrical connector.
Release the retaining