Opel Insignia: Repair Instructions

Wire to Wire Repair - Seats

Special Tools

• EL-38125-10 Splice Sleeve Crimping Tool
• J-38125-5A Ultra Torch Special Tool
• J-38125-8 Splice Sleeve Crimping Tool

For equivalent regional tools, refer to Special Tools.

WARNING: In order to reduce the risk of personal injury, loss of high voltage isolation to ground and higher system impedance, do not attempt to repair any HV wiring, connector, or terminal that is damaged. High voltage coaxial type cables are not repairable. Never attempt to repair a coaxial type cable. The entire cable/harness or component must be replaced. In order to maintain system integrity and personal safety, never attempt to repair any high voltage wiring, cables, or terminals. Performing this procedure on high voltage circuits may result in serious injury or death.

CAUTION: If the SIR/SRS wiring, connector, or terminal is damaged, the affected wiring harness must be replaced. Do not attempt to repair the wiring, connector, or terminals. Any attempt to repair the wires, connectors, or terminals could result in performance problems of the SIR/SRS System.

Operations on restraint systems must only be performed by trained and qualified personnel.

NOTE: If the wiring harness internal to the transmission is damaged, the wiring harness must be replaced. The use of splice sleeves in an attempt to repair the internal transmission wires, connectors, or terminals could result in performance issues.

NOTE: Do not splice wires in Door Harness Grommets.

NOTE: Use only DuraSeal splice sleeves. Other splice sleeves may not protect the splice from moisture or provide a good electrical connection.

Use DuraSeal splice sleeves to form a one-to-one splice on all types of insulation except Tefzel and coaxial. Use DuraSeal splice sleeves where there are special requirements such as moisture sealing.

Follow the instructions below in order to splice copper wire using DuraSeal splice sleeves.

NOTE: Perform the following procedures in the listed order. Repeat the procedure if any wire strands are damaged. Obtain a clean strip with all of the wire strands intact.

1. Open the harness by removing any tape:

• Use a sewing seam ripper, available from sewing supply stores, in order to cut open the harness in order to avoid wire insulation damage.
• Use the DuraSeal splice sleeves on all types of insulation except Tefzel and coaxial.
• Do not use the crimp and DuraSeal splice sleeve to form a splice with more than 2 wires coming together.

2. Cut as little wire off the harness as possible. Extra wire length may be needed in order to change the location of a splice.

Adjust splice locations so that each splice is at least 40 mm (1.5 in) away from the other splices, harness branches, or connectors.

3. Strip the insulation:

• When adding a length of wire to the existing harness, use the same size wire as the original wire.
• Perform one of the following items in order to find the correct wire size:
  • Find the wire on the schematic and convert to regional wiring gauge size.
  • When the wire size is not known, begin with the largest opening in the wire stripper and work down until achieving a clean strip of the insulation.
• Strip approximately 5.0 mm (0.20 in) of insulation from each wire to be spliced.
• Do not nick or cut any of the strands. Inspect the stripped wire for nicks or cut strands.
• If the wire is damaged, repeat this procedure after removing the damaged section.

4. For high temperature wiring, slide a section of high temperature SCT1 shrink tubing down the length of wire to be spliced. Ensure that the shrink tubing will not interfere with the splice procedure.

5. Select the proper DuraSeal splice sleeve according to the wire size. Refer to the above table at the beginning of the repair procedure for the color coding of the DuraSeal splice sleeves and the crimp tool nests.

6.

The EL-38125-10 splice sleeve crimping tool has four crimp nests. The largest crimp nest (4) is used for crimping 10 and 12 gauge wires. The second largest crimp nest (3) is used for crimping 14 and 16 gauge wires. The third largest crimp nest (2) is used for crimping 18 and 20 gauge wires. The smallest crimp nest (1) is used for crimping 22 to 26 gauge wires. The crimp nests are referenced in the table (farther above) under the crimp tool nest color.

7.

The J-38125-8 splice sleeve crimping tool has three crimp nests. The largest crimp nest (3) is used for crimping 10 and 12 gauge wires. The second largest crimp nest (2) is used for crimping 14 and 16 gauge wires. The smallest crimp nest (1) is used for crimping 18 to 20 gauge wires. The crimp nests are referenced in the table (farther above) under the crimp tool nest color.

8. Use the splice sleeve crimp tool in order to position the DuraSeal splice sleeve in the proper color nest of the splice sleeve crimp tool. For the four crimp nest tool, use the three largest crimp nests to crimp the splice sleeves. For the three crimp nest tool, use all three crimp nests to crimp the splice sleeves. Use the four and three crimp tool diagrams (above) and the table (farther above) to match the splice sleeve with the correct crimp nest. The crimp tool diagram callout numbers match the numbers in the table (under crimp tool nest color).

9.

Place the DuraSeal splice sleeve in the nest. Ensure that the crimp falls midway between the end of the barrel and the stop. The sleeve has a stop (3) in the middle of the barrel (2) in order to prevent the wire (1) from going further. Close the hand crimper handles slightly in order to firmly hold the DuraSeal splice sleeve in the proper nest.

10.

Insert the wire into the splice sleeve barrel until the wire hits the barrel stop.

11. Tightly close the handles of the crimp tool until the crimper handles open when released.

The crimper handles will not open until the proper amount of pressure is applied to the DuraSeal splice sleeve. Repeat steps 4 and 6 for the opposite end of the splice.

12.

Using the heat torch, apply heat to the crimped area of the barrel.

13. Start in the middle and gradually move the heat barrel to the open ends of the tubing:

• The tubing will shrink completely as the heat is moved along the insulation.
• A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved.

High Temperature Wiring Repairs

Use the following procedures to perform high temperature wiring repairs:

1. Center the high temperature SCT1 shrink tube over the DuraSeal splice sleeve.

2. Using the heat torch, apply heat to the high temperature heat shrink tubing.

3. Gradually move the heat from the center to the open end of the tubing:

• The tubing will shrink completely as the heat is moved along the insulation.
• A small amount of sealant will come out of the end of the tubing when sufficient shrinkage is achieved.

4. Replace any reflective tape and clips that may have been removed during the repair.

Connector Reconnection - Seats

Special Tools

EL-35616 Terminal Test Probe Kit

For equivalent regional tools, refer to Special Tools.

When the condition is not currently present, but is indicated in DTC history, the cause may be intermittent. An intermittent may also be the cause when there is a customer complaint, but the symptom cannot be duplicated. Refer to the Symptom Table of the system that is suspect of causing the condition before trying to locate an intermittent condition.

Most intermittent conditions are caused by faulty electrical connections or wiring. Inspect for the following items:

• Wiring broken inside the insulation
• Poor connection between the male and female terminal at a connector
• Poor terminal to wire connection - Some conditions which fall under this description are poor crimps, poor solder joints, crimping over the wire insulation rather than the wire itself, and corrosion in the wire to terminal contact area, etc.
• Pierced or damaged insulation can allow moisture to enter the wiring causing corrosion. The conductor can corrode inside the insulation, with little visible evidence. Look for swollen and stiff sections of wire in the suspect circuits.
• Wiring which has been pinched, cut, or its insulation rubbed through may cause an intermittent open or short as the bare area touches other wiring or parts of the vehicle.
• Wiring that comes in contact with hot or exhaust components
• Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required, in order to verify the customer concern.
• Refer to Testing for Electrical Intermittents for test procedures to detect intermittent open, high resistance, short to ground, and short to voltage conditions.
• Refer to Scan Tool Snapshot Procedure for advanced intermittent diagnosis and Vehicle Data Recorder operation.

Testing for Terminal Fretting

Some intermittent conditions can be caused by wire terminal fretting corrosion. Fretting corrosion is a build-up of insulating, oxidized wear debris that can form when there is a small motion between electrical contacts. The oxidized wear debris can pile up enough at the electrical contact spots that the electrical resistance across the connection increases. Movement between the contacting surfaces as small as 10 to 100 micrometer can cause fretting. To put this in perspective, a sheet of paper is about 100 micrometer thick, so fretting motion is small and hard to see. Vibration and thermal expansion/contraction are the main sources that create fretting motion. Since vehicles vibrate and can experience large temperature swings, they are a good source for fretting motion. Tin, copper, nickel, and iron surfaces are all susceptible to fretting corrosion. Fretting corrosion can be difficult to see but it looks like small, dark smudges on the terminals contact surface.

To correct a fretting condition disconnect the suspect connector and add dielectric grease / lubricant (Nyogel 760G or equivalent, meeting GM specification 9986087) to both sides of the connector terminals. Then reconnect the connector and wipe away any excess lubricant. This will correct the additional terminal contact resistance due to the terminal fretting corrosion.

Testing for Proper Terminal Contact

It is important to test terminal contact at the component and any inline connectors before replacing a suspect component. Mating terminals must be inspected to ensure good terminal contact. A poor connection between the male and female terminal at a connector may be the result of contamination or deformation.

Contamination may be caused by the connector halves being improperly connected. A missing or damaged connector seal, damage to the connector itself, or exposing the terminals to moisture and dirt can also cause contamination. Contamination, usually in the underhood or underbody connectors, leads to terminal corrosion, causing an open circuit or intermittently open circuit.

Deformation is caused by probing the mating side of a connector terminal without the proper adapter.

Always use the EL-35616 kit when probing connectors. Other causes of terminal deformation are improperly joining the connector halves, or repeatedly separating and joining the connector halves.

Deformation, usually to the female terminal contact tang, can result in poor terminal contact causing an open or intermittently open circuit.

Testing for Proper Terminal Contact in Bussed Electrical Centers

It is very important to use the correct test adapter when testing for proper terminal contact of fuses and relays in a bussed electrical center. Use the EL-35616 kit to test for proper terminal contact. Failure to use the EL-35616 kit can result in improper diagnosis of the bussed electrical center.

Follow the procedure below in order to test terminal contact:

1. Separate the connector halves.

2. Visually inspect the connector halves for contamination. Contamination may result in a white or green build-up within the connector body or between terminals. This causes high terminal resistance, intermittent contact, or an open circuit. An underhood or underbody connector that shows signs of contamination should be replaced in its entirety: terminals, seals, and connector body.

3. Using an equivalent male terminal/terminated lead, verify that the retention force is significantly different between a known good terminal and the suspect terminal. Replace the female terminal in question.

Flat Wire Connectors

There are no serviceable parts for flat wire connectors on the harness side or the component side.

Follow the procedure below in order to test terminal contact:

1. Remove the component in question.

2. Visually inspect each side of the connector for signs of contamination. Avoid touching either side of the connector as oil from your skin may be a source of contamination as well.

3. Visually inspect the terminal bearing surfaces of the flat wire circuits for splits, cracks, or other imperfections that could cause poor terminal contact. Visually inspect the component side connector to ensure that all of the terminals are uniform and free of damage or deformation.

4. Insert the appropriate adapter into the flat wire harness connector in order to test the circuit in question.

Control Module/Component Voltage and Grounds

Poor voltage or ground connections can cause widely varying symptoms.

• Test all control module voltage supply circuits. Many vehicles have multiple circuits supplying voltage to a control module. Other components in the system may have separate voltage supply circuits that may also need to be tested. Inspect connections at the module/component connectors, fuses, and any intermediate connections between the voltage source and the module/component. A test lamp or a DMM may indicate that voltage is present, but neither tests the ability of the circuit to carry sufficient current. Operate the component to test the ability of the circuit to carry sufficient current. Refer to Circuit Testing and Power Distribution Wiring Schematics.
• Test all control module ground and system ground circuits. The control module may have multiple ground circuits. Other components in the system may have separate grounds that may also need to be tested. Inspect grounds for clean and tight connections at the grounding point. Inspect the connections at the component and in splice packs, where applicable. Operate the component to test the ability of the circuit to carry sufficient current. Refer to Circuit Testing and Ground Distribution Wiring Schematics.

Temperature Sensitivity

• An intermittent condition may occur when a component/connection reaches normal operating temperature. The condition may occur only when the component/connection is cold, or only when the component/connection is hot.
• Freeze Frame, Failure Records, Snapshot, or Vehicle Data Recorder data may help with this type of intermittent condition, where applicable.
• If the intermittent is related to heat, review the data for a relationship with the following:
  • High ambient temperatures
  • Underhood/engine generated heat
  • Circuit generated heat due to a poor connection, or high electrical load
  • Higher than normal load conditions, towing, etc.
• If the intermittent is related to cold, review the data for the following:
  • Low ambient temperatures - In extremely low temperatures, ice may form in a connection or component. Inspect for water intrusion.
  • The condition only occurs on a cold start.
  • The condition goes away when the vehicle warms up.
• Information from the customer may help to determine if the trouble follows a pattern that is temperature related.
• If temperature is suspected of causing an intermittent fault condition, attempt to duplicate the condition. Refer to Inducing Intermittent Fault Conditions in order to duplicate the conditions required.

Electromagnetic Interference and Electrical Noise

Some electrical components/circuits are sensitive to electromagnetic interference or other types of electrical noise. Inspect for the following conditions:

• A harness that is too close routed to high voltage/high current devices such as secondary ignition components, motors, generator etc. These components may induce electrical noise on a circuit that could interfere with normal circuit operation.
• Electrical system interference caused by a malfunctioning relay, or a control module driven solenoid or switch. These conditions can cause a sharp electrical surge. Normally, the condition will occur when the malfunctioning component is operating.
• Installation of non-factory or aftermarket add on accessories such as lights, 2-way radios, amplifiers, electric motors, remote starters, alarm systems, cell phones, etc. These accessories may create interference in other circuits while operating and the interference would disappear when the accessory is not operating. Refer to Checking Aftermarket Accessories.
• Test for an open diode across the A/C compressor clutch and for other open diodes. Some relays may contain a clamping diode.
• The generator may be allowing AC noise into the electrical system.

Driver or Passenger Seat Adjuster Switch Replacement

Preliminary Procedure

Front Seat Cushion Outer Finish Cover Replacement (Manual) or Front Seat Cushion Outer Finish Cover Replacement (Power).

1. Front Seat Recliner Knob
2. Front Seat Adjuster Knob
3. Driver or Passenger Seat Adjuster Switch
   Procedure
   Disconnect the electrical connector.

FRONT SEAT ADJUSTER MEMORY SWITCH REPLACEMENT

Preliminary Procedure

Front Seat Cushion Outer Finish Cover Replacement (Manual) or Front Seat Cushion Outer Finish Cover Replacement (Power).

1. Front Seat Adjuster Memory Switch

FRONT SEAT ADJUSTER MEMORY MODULE BRACKET REPLACEMENT

Preliminary Procedures

1. Front Seat Cushion Cover and Pad Replacement (Except GS) or Front Seat Cushion Cover and Pad Replacement (GS).

2. Driver or Passenger Seat Adjuster Memory Module Replacement

1. Front Seat Adjuster Memory Module Bracket Bolt [4x]
   CAUTION: Fastener Caution
   Tighten 4.7N.m (42 lb in)
2. Front Seat Adjuster Memory Module Bracket

DRIVER OR PASSENGER SEAT ADJUSTER MEMORY MODULE REPLACEMENT

Preliminary Procedure

Driver or Passenger Seat Removal and Installation.

1. Driver Seat Adjuster Memory Bolt (Qty: 3)
   CAUTION: Fastener Caution
   Tighten 2.5N.m (22 lb in)
2. Driver or Passenger Seat Adjuster Memory Module
   Procedure
   Disconnect the electrical connector.

FRONT SEAT MASSAGE SWITCH REPLACEMENT (GS)

Preliminary Procedure

Front Seat Cushion Outer Finish Cover Replacement (Manual) or Front Seat Cushion Outer Finish Cover Replacement (Power).

1. Front Seat Massage Switch

FRONT SEAT TILT ADJUSTER ACTUATOR REPLACEMENT

Preliminary Procedures

1. Set the seat to it's highest position.

2. Driver or Passenger Seat Removal and Installation.

1. Front Seat Tilt Adjuster Actuator Bolt
   CAUTION: Fastener Caution
   Procedure
   Remove the securing bolt from the actuator and the cushion frame.
   Tighten 8N.m (71 lb in)
2. Front Seat Tilt Adjuster Actuator
   Procedure
   1. Disconnect the electrical connector.
   2. Remove the tilt adjuster actuator by pulling it downward from the cushion frame.

DRIVER OR PASSENGER SEAT VERTICAL ADJUSTER ACTUATOR REPLACEMENT

Preliminary Procedure

Front Seat Cushion Cover and Pad Replacement (Except GS) or Front Seat Cushion Cover and Pad Replacement (GS).

1. Driver or Passenger Seat Adjuster Vertical Actuator Nut [3x]
   CAUTION: Fastener Caution
   Tighten 23N.m (17 lb ft)
2. Driver or Passenger Seat Adjuster Vertical Actuator Bracket
3. Driver or Passenger Seat Adjuster Vertical Actuator
   Procedure
   Disconnect the electrical connector.

DRIVER OR PASSENGER SEAT LUMBAR CONTROL SWITCH REPLACEMENT

Preliminary Procedure

Front Seat Cushion Outer Finish Cover Replacement (Manual) or Front Seat Cushion Outer Finish Cover Replacement (Power).

1. Driver or Passenger Seat Lumbar Control Switch
   Procedure
   Disconnect the electrical connector.

FRONT SEAT BACK LUMBAR REPLACEMENT (2 WAY)

Preliminary Procedure

Front Seat Back Cover and Pad Replacement (Except GS) or Front Seat Back Cover and Pad Replacement (GS).

1. Front Seat Back Lumbar
   Procedure
   Disconnect the electrical connector.

FRONT SEAT BACK LUMBAR REPLACEMENT (GS)

Preliminary Procedure

Front Seat Back Cover and Pad Replacement (Except GS) or Front Seat Back Cover and Pad Replacement (GS).

1. Front Seat Back Lumbar
   Procedure
   1. Disconnect the electrical connectors.
   2. Release the retainers.

FRONT SEAT BACK LUMBAR REPLACEMENT (4 WAY)

Preliminary Procedure

Front Seat Back Cover and Pad Replacement (Except GS) or Front Seat Back Cover and Pad Replacement (GS).

1. Front Seat Back Lumbar
   Procedure
   1. Disconnect the electrical connectors.
   2. Release the retainers.

DRIVER OR PASSENGER SEAT RECLINER ACTUATOR REPLACEMENT (Except GS)

Preliminary Procedure

Front Seat Back Cover and Pad Replacement (Except GS) or Front Seat Back Cover and Pad Replacement (GS) - Reposition.

1. Driver or Passenger Seat Recliner Actuator Rod
   Procedure
   Use a flat-bladed tool to push upward on the front seat recliner hub tab while gently tapping the recliner rod outward until the rod is free of the recliner motor.
2. Driver or Passenger Seat Recliner Actuator Bolt
   CAUTION: Refer to Fastener Caution.
   Tighten 6 N.m (53 lb in)
3. Driver or Passenger Seat Recliner Actuator
   Procedure
   1. Disconnect the electrical connector.
   2. Pull up on the trim cover to gain access to the seat recliner actuator bolt.
   3. Remove the seat recliner actuator.

DRIVER OR PASSENGER SEAT RECLINER ACTUATOR REPLACEMENT (GS)

Preliminary Procedure

Front Seat Head Restraint Panel Replacement (GS).

1. Driver or Passenger Seat Recliner Actuator Rod
   Procedure
   Use a flat-bladed tool to push upward on the front seat recliner hub tab while gently tapping the recliner rod outward until the rod is free of the recliner motor.
2. Driver or Passenger Seat Recliner Actuator Bolt
   CAUTION: Refer to Fastener Caution.
   Tighten 6 N.m (53 lb in)
3. Driver or Passenger Seat Recliner Actuator
   Procedure
   1. Disconnect the electrical connector.
   2. Pull up on the trim cover to gain access to the seat recliner actuator bolt.
   3. Remove the seat recliner actuator.

FRONT SEAT WIRING HARNESS REPLACEMENT

WARNING: Refer to SIR Warning.

Preliminary Procedures

1. SIR Disabling and Enabling.

2. Driver or Passenger Seat Removal and Installation.

1. Front Seat Wiring Harness

NOTE: Typical wiring harness shown, individual harness may be different due to option content. Various seat components may need to be removed from the seat to access the harness depending on seat and content options.

REAR SEAT RECLINER ACTUATOR REPLACEMENT

Preliminary Procedure

Rear Seat Back Cushion Cover and Pad Replacement - Left Side , or Rear Seat Back Cushion Cover and Pad Replacement - Right Side (40 Percent Seat) or Rear Seat Back Cushion Cover and Pad Replacement - Right Side (60 Percent Seat).

1. Rear Seat Recliner Actuator Bowden Cable
   Procedure
   Disengage bowden cable from rear seat recliner actuator and bracket.
2. Rear Seat Recliner Actuator Washer (Qty: 2)
   Procedure
   Use suitable tool to remove the washer from rear seat recliner actuator bracket.
3. Rear Seat Recliner Actuator
   Procedure
   Disconnect the electrical connector.

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