Opel Insignia: Repair Instructions

Forward Range Radar Module Inspection

Inspection Procedure

1.

CONTROL MODULE DTC CHECK - Using a scan tool, perform the Vehicle DTC Information function - Verify there are no current control module DTCs set. If any DTC is set, refer to Diagnostic Trouble Code (DTC) List - Vehicle.

2. Check the alignment of the forward range radar module (1). The forward range radar module has to be aligned vertically and parallel to the front bumper impact bar.

3. Inspect all studs (2) for proper seat. If damaged, replace the bracket. Refer to Forward Range Radar Bracket Replacement.

4. Inspect the forward range radar module bracket (3) for paint cracks and deformations. Do NOT repair any cracks or misalignments. If damaged, replace the bracket. Refer to Forward Range Radar Bracket Replacement.

5. Inspect the forward range radar module (1) for paint cracks, scratches and deformations. Do NOT repair any cracks, scratches or misalignments. If damaged, replace the module. Refer to Forward Range Radar Sensor Replacement.

6. Inspect the wiring harness plug and the terminal of the forward range radar module for any damage.

7. Check the front bumper fascia energy absorber for damage and misalignment. Replace the front bumper fascia energy absorber if necessary. Refer to Front Bumper Fascia Energy Absorber Replacement.

8. When installing the front bumper fascia ensure that absolutely no objects (e.g. Wiring harness, Snow, Sticks) are in front of the forward range radar module and between the forward range radar module and the front bumper fascia.

FORWARD RANGE RADAR BRACKET REPLACEMENT

Preliminary Procedure

Forward Range Radar Sensor Replacement.

1. Forward Range Radar Bracket Bolt [5x]
   CAUTION: Fastener Caution
   Tighten 9 N.m (80 lb in)
2. Forward Range Radar Bracket
   Procedure
   Reposition the wiring harness.

FORWARD RANGE RADAR SENSOR REPLACEMENT

Preliminary Procedure

Front Bumper Fascia Replacement.

1. Forward Range Radar Sensor Nut [3x]
   CAUTION: Fastener Caution
   Tighten 9 N.m (80 lb in)
2. Forward Range Radar Sensor
   CAUTION:
   Do NOT apply paint to the Forward Range Radar Module. Always cover the module before applying paint or other coatings in the area around the module. Failure to protect the module may result in reduced functionality of the module.

   Procedure

   1. Disconnect the electrical connector.
   2. Control Module References for programming and setup information, if required.

ACTIVE SAFETY CONTROL MODULE REPLACEMENT

Preliminary Procedure

Rear Compartment Side Trim Replacement - Left Side (5-Door Wagon 35) Rear Compartment Side Trim Replacement - Left Side (Hatchback) - Reposition.

1. Active Safety Control Module
   Procedure
   1. Disconnect the electrical connectors.
   2. Release the locking retainer from the active safety control module bracket.
   3. Perform the necessary programming and setup procedure: Control Module References

FORWARD COLLISION ALERT DISPLAY REPLACEMENT

Preliminary Procedure

Forward Collision Alert Display Bezel Replacement.

1. Forward Collision Alert Display Bolt
   CAUTION: Fastener Caution
   Tighten 2.5 N.m (22 lb in)
2. Forward Collision Alert Display

SIDE OBJECT SENSING ALERT MODULE REPLACEMENT

Preliminary Procedure

Rear Bumper Fascia Replacement (5-Door Hatchback 68) Rear Bumper Fascia Replacement (5-Door Wagon 35).

1. Side Object Sensing Alert Module Bolt
   CAUTION: Fastener Caution
   Tighten 2.5 N.m (22 lb in)
2. Side Object Sensing Alert Module
   Procedure
   1. Disconnect the electrical connector.
   2. Release the tab retainers and slide the module out of the retaining bracket.
   3. Control Module References for programming and setup information, if required.

FRONT VIEW CAMERA REPLACEMENT

Preliminary Procedure

Windshield Multifunction Sensor Mount Bracket Cover Replacement.

1. Front View Camera
   Procedure
   1. Gently depress top center tabs on bracket to release camera.
   2. Disconnect the electrical connector.
   3. Control Module References for programming and setup information, if required.

Front View Camera Module Learn

Calibration (without UGN)

NOTE: Do NOT swap cameras between vehicles, it is not approved and a VIN mismatch will occur.

The calibration process for the front view camera system is necessary when a front view camera module is replaced by a new one. This process is required anytime the module is removed from it's bracket and the frontview camera module has been mounted again properly. This process shall be completed within 3 - 5 minutes when the correct driving conditions are met. If conditions are not met, the front view camera module shall continuously run the service point calibration until successfully completed.

This process shall work across ignition cycles and shall not be required to be re-initialized at start up. If the Lane Departure Warning Switch is pressed during calibration, the indictor will flash momentarily and then stay out - this is normal operation.

The calibration procedure may start automatically after SPS programming is complete. During this time the Lane Departure Warning amber indicator will illuminate.

To calibrate the front camera, operate the vehicle in the following conditions until the calibration is complete:

• Clean windshield.
• Avoid lane changes.
• Maintain vehicle speeds between 56 - 90 km/h (35 - 56 MPH).
• Ensure the road contains visible references (well defined lane markings, curbs, etc.).

Once the procedure is complete, the amber indicator will turn off. Shortly after the green ready to assist light should turn on as long as all conditions are met for normal operation. The system is then ready to assist.

Calibration (with UGN)

NOTE: Do NOT swap cameras between vehicles, it is not approved and a VIN mismatch will occur.

New modules must be SPS programmed prior to calibration , refer to Control Module References

The calibration process for the front view camera system is necessary when a front view camera module is replaced by a new one. This process is required anytime the module is removed from it's bracket and the frontview camera module has been mounted again properly. This process shall be completed within 3 - 5 minutes when the correct driving conditions are met. If conditions are not met, the front view camera module shall continuously run the service point calibration until successfully completed.

This process shall work across ignition cycles and shall not be required to be re-initialized at start up. If the Lane Departure Warning Switch is pressed during calibration, the indictor will flash momentarily and then stay out - this is normal operation.

NOTE: Calibration is not required if the existing module was reprogrammed. This procedure only needs to be conducted if the module was replaced.

Once SPS programming is complete, it is necessary to initiate the calibration using a scantool. During this time the "Service Driver Assist" service message will be displayed.

NOTE: It is necessary to have the scantool connected during the entire process.

Do not back out of the screen or press any other buttons.

To calibrate the front camera, operate the vehicle in the following conditions until the calibration is complete:

• Clean windshield.
• Avoid aggressive and frequent lane changes. Occasional lane changes are preferred.
• Maintain vehicle speeds between 56 - 120 km/h (35 - 75 MPH).
• Ensure the road contains visible references (well defined lane markings, etc.).

Once the procedure is complete, the service message will turn off and normal operation will resume.

Shortly after the green ready to assist light should turn on as long as all conditions are met for normal operation. The system is then ready to assist.

If Slow to Calibrate

The ideal calibration condition is driving on a 2 lane divided highway with markings on both sides of the lane. One or more of the following conditions may increase the length of time required to complete the self-calibration procedure:

• Heavy traffic
• Stop and go traffic
• Mountain roads
• Curves in roadway
• Poor contrast lane markings
• Botts' Dots type lane markings
• Operating the vehicle at speeds greater than recommended
• Driving through snow or fog, or driving directly into the sun
• Camera not properly installed. Verify it is snapped into tabs and is secure. Refer to Front View Camera Replacement.

Calibration Procedure (Required for North American SPS users)

1. Apply the parking brake.

2. Place the transmission in Park (if applicable)

3. Install scan tool

4. Navigate to the module diagnostics menu

5. Select Frontview Camera Module

6. Select Configuration/Reset Functions menu Item

7. Select the Frontview Camera Learn procedure and follow the directions displayed on the screen.

8. Drive the vehicle to complete calibration.

No Calibration

Conditions that will prevent completion of the self-calibration procedure:

• Dirty windshield glass or obstruction on windshield
• Operating the vehicle with speed less than 56 km/h (35 MPH)
• No visible lane markings
• Severe weather where lane markings cannot be seen
• Camera not properly installed. Verify it is snapped into tabs and is secure. Refer to Front View Camera Replacement.

Radar Sensor Module - Long Range Learn

NOTE: Adaptive Cruise Temporarily Unavailable service message may be displayed if this calibration procedure has to be performed. The radar may have become misaligned.

After replacing and programming the Long Range Radar Sensor Module, it is necessary to perform a calibration procedure to align the radar. This is indicated to the technician by DTC B101E 4B.

Calibration is performed while driving the vehicle with the scantool connected. Calibration is initialized using a scantool and the scantool must remain connected until calibration is complete. During this time the "Service Driver Assist" service message will be displayed. Once the procedure is complete, the service message will turn off and normal operation will resume.

Calibration is not required if the existing module was reprogrammed only. Calibration needs to be conducted if the module was replaced or removed and re-secured.

If calibration is not successful, it could be due to improper driving environment, module and bracket assembly bent out of position or incorrect module mounting. A typical driving environment is usually sufficient to calibrate the module within 10 - 30 minutes. Visually inspect for damaged, bent, or broken Long Range Radar bracket. Brackets out of level more than 2 degrees will not calibrate or self-learn.

Discuss with the customer about vehicle history and possible past accident. Replace bracket if damaged.

Calibration Procedure

1. Verify no other DTCs except for B101E 4B Electronic Control Unit Software are present.

• If other DTCs are present

Refer to service information and repair as necessary.

• Go to next step: If no other DTCs are present

2. Prior to driving the vehicle make sure the surface in front of the radar (Cadillac emblem) is clean.

Also verify the mounting area is not damaged and allows the module to face the intended direction.

3. Prepare scantool to be mobile for Long Range Radar Calibration driving phase. The scantool needs to stay connected during the driving phase of the calibration.

4. Engine running.

5. Initiate calibration using Long Range Radar Sensor Module Learn in the scantool. The driver information display will display "Service Driver Assist" message during calibration.

NOTE: Do not back out of screen or press any other buttons until the calibration is complete.

6. Drive the vehicle within the following conditions for 10 - 30 minutes or until calibration is complete. The "Service Driver Assist" message will turn off when calibration is complete.

• Drive at speeds greater than 56 kph (35 mph)
• Minimize tight curves
• Avoid extreme acceleration or deceleration
• Follow one or multiple vehicles. (typical vehicle traffic is sufficient, but vehicles 30 - 50 m (100 - 165 ft) away are most effective at decreasing the calibration time)
• Drive in an environment that has stationary objects on the side of the road (street signs, guard rails, mail boxes, fences, etc)

7. Verify proper calibration by observing that the "Service Driver Assist" message turns off within 10 - 30 minutes of normal driving.

• If "Service Driver Assist" message fails to turn off

1. Verify correct operating conditions were met
   • If incorrect driving environment, refer to If Slow to Calibrate and repeat calibration procedure following recommended operating conditions.
   • Go to next step: If correct driving environment
2. Verify DTC B390C 66 Incorrect Mounting is not set
   • If B390C 66 is set

     Refer to DTC B390C.

   • Go to next step: If B390C 66 is not set

• Go to next step: If "Service Driver Assist" message turns off

8. Drive at speeds greater than 40 kph (25 mph) and verify engagement of Adaptive Cruise Control (cruise control icon will change from white to green)

• If Adaptive Cruise Control will not engage

Check vehicle for DTCs and correct as required.

• Go to next step: If Adaptive Cruise Control engages

9. All OK.

If Slow to Calibrate

The ideal calibration condition is driving on a freeway or two lane road with medium traffic. One or more of the following conditions may increase the length of time required to complete the self-calibration procedure:

• Visually inspect for damaged, bent, or broken Long Range Radar bracket. Brackets out of level more than 2 degrees will not calibrate or self-learn. Discuss with the customer about vehicle history and possible past accident. Replace bracket if damaged.
• Heavy traffic - following too close behind vehicles for long periods (more than 40 min)
• Stop and go or very slow traffic
• Mountain roads
• Constant sharp curves in roadway
• No traffic - if no traffic is available, may need to add vehicle ahead to support calibration
• Limited or no stationary structures on side of the road - need structures such as street signs, guard rails, mail boxes, parked cars, etc.
• Driving in tunnels

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