According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2008-2022 Opel Insignia has 8 documented known issues, with 5 rated critical. The most serious are Insignia A 2.0 CDTI Premature Timing Belt / Water Pump Failure (Engine Destruction) ($550-$6,500 repair), Insignia B 2.0 Diesel Fuel Line Chafing — Fire Risk (KBA Recall E191905110 / 20-C-012) ($0-$0 repair), Insignia A 2.0 CDTI EGR Cooler Crack (Coolant Loss into Intake) ($600-$1,800 repair), Insignia A Aisin AF40 Harsh Shifts / Shudder ($150-$2,500 repair) and Insignia A 4x4 Haldex Coupling & Rear Differential Failure (Oil Mixing / Pump Failure) ($800-$4,500 repair). Across all issues with published estimates, repair costs range from $120 to $6,500. DIY maintenance guides at au7o.io.
Insignia A 2.0 CDTI EGR Cooler Crack (Coolant Loss into Intake)
100K-180K
Insignia A Aisin AF40 Harsh Shifts / Shudder
100K-160K
050K100K150K200K mi
The 2.0 CDTI diesel (A20DTH/A20DTJ) in the Insignia A uses a timing belt on an interference engine, and German and UK owner communities document repeated belt failures well before the official 120,000-150,000 km / 10-year change interval. A common trigger is the belt-driven water pump seizing, which shreds or melts the belt — one documented UK case occurred at just 15,000 miles, another on a 2012 (62-plate) car. When the belt snaps, pistons strike the open valves, bending valves and snapping rocker arms, which typically destroys the cylinder head and often the whole engine. German maintenance guides explicitly warn of 'kapitaler Motorschaden' if the interval is stretched, and forum threads on Motor-Talk and Insignia-Freunde collect multiple total-loss engine failures.
Common Symptoms
Sudden engine cut-out while driving with no restart
Engine cranks but will not start after the failure
Rattling or slapping noise from the timing cover area
Whining or grinding from a failing water pump
Unexplained coolant loss near the front of the engine
How to Fix
Replace the timing belt kit early and completely: belt, tensioner, idler rollers AND the water pump together, ideally every 90,000-100,000 km or 6 years rather than waiting for the maximum factory interval (German workshops quote roughly 450-750 EUR for the full job). Investigate any whining or grinding from the belt area or unexplained coolant loss immediately, since a failing water pump is the most common belt killer. If the belt has already snapped, the engine must be stripped: expect bent valves, damaged rockers and possible piston contact — repairs range from a cylinder head overhaul to a replacement engine.
What you need to fix it
Only diagnosis- and fitment-reviewed repair parts are linked here.
TBK433-6332-2nd Insignia 2.0 CDTi timing-belt and water-pump kit
Confirm VIN, engine code and 199-tooth/24 mm OE configuration; exclude later B20 engines.
Official KBA-supervised recall: on Insignia B models with the 2.0-liter diesel built between July 2016 and November 2018, a faulty clamp/bracket can rub through the fuel line. Leaking diesel can reach hot engine components and cause an engine-bay fire. Roughly 45,000 vehicles were affected worldwide, 21,436 of them in Germany. The recall runs under KBA reference E191905110 (Opel campaign 20-C-012); German trade press (kfz-betrieb) and owner forums (Motor-Talk, 'Rückruf KBA 9541') document the campaign. The workshop remedy takes about 30 minutes: the clamp position and fuel line are inspected, the line is replaced if chafed, a spacer is exchanged and protective hose sleeving is added.
Common Symptoms
Diesel smell in or around the engine bay
Visible fuel weeping or wet fuel line at the chafe point
Often no warning at all before a leak develops
In the worst case, smoke or fire from the engine compartment
How to Fix
Check whether the recall has been performed: enter the VIN on Opel's official recall-check page or ask any Opel dealer to query the campaign status (KBA E191905110 / Opel 20-C-012). If open, the dealer inspects the fuel line routing, replaces the damaged line where needed, fits a new spacer and adds protective sleeving — free of charge, about 30 minutes. Until the fix is done, investigate any diesel smell or visible wetness on fuel lines near the engine immediately and do not keep driving with an active fuel leak.
The A20DT/A20DTH 2.0 CDTI EGR cooler develops internal cracks, allowing coolant to leak into the intake. Symptoms: white smoke from exhaust, mysterious coolant loss with no external leak, sweet smell, eventual no-start as cylinders flood. Common at 100,000-180,000 km. Same engine in Astra J, Zafira C, Cascada.
Common Symptoms
white exhaust smoke
mysterious coolant loss
sweet smell
no start
P-codes
How to Fix
EGR cooler replacement €600-€1,200 incl. labor. If coolant has been pulled into cylinders, hydrolock check required. Some independents recommend EGR delete + remap — illegal in most markets and disqualifies TÜV inspection.
What you need to fix it
Only diagnosis- and fitment-reviewed repair parts are linked here.
Genuine 55590953/55572962 EGR cooler and valve repair kit
Insignia A 2009-2017 2.0 CDTi engine family listed as A20DT/A20DTC/A20DTE/A20DTH/A20DTJ/A20DTL/A20DTR and related Y/Z20 codes. Confirm VIN and OE 55590953/55572962.
The Aisin AF40 6-speed automatic in Insignia A (2008-2017) develops harsh shifts, shudder during lock-up, and delayed engagement, typically by 100,000-160,000 km. Root cause is degraded ATF and worn solenoids; Opel's "lifetime fill" claim is widely disputed.
Common Symptoms
harsh shifts
shudder at light throttle
delayed engagement
limp mode
How to Fix
Drain-and-fill ATF every 60,000 km using Aisin JWS3309 / Dexron VI-compatible fluid (~€150-€250 DIY). Solenoid pack replacement if shifts remain harsh (€500-€900). Full mechatronic / valve body rebuild €1,500-€2,500. Severe shudder may indicate torque converter wear.
What you need to fix it
Only diagnosis- and fitment-reviewed repair parts are linked here.
Aisin ATF-93001 AW-1 transmission fluid 1 L
Confirm VIN, transmission tag, quantity and level procedure.
Insignia A 4x4 models (including the OPC) suffer chronic failures of the rear drive unit: the shaft seal (Simmerring) between the rear differential and the Haldex coupling degrades, letting the two separate oil fills mix into sludge, while the Haldex hydraulic pump fails from contaminated, never-changed fluid. German forum consensus (Motor-Talk, Insignia-Freunde, opel-turbo.de) is that the root aggravator is Opel specifying NO regular Haldex oil change interval — unlike VW/Audi cars using the same Haldex hardware, which fail far less often. Symptoms are knocking, banging and juddering from the rear axle in tight low-speed turns, often initially without fault codes; failures are documented from under 43,000 km. A complete replacement rear axle drive unit costs around 4,000 EUR (differential alone ~2,000 EUR), and Opel historically covered up to 90% on goodwill for some owners.
Common Symptoms
Knocking or banging from the rear axle in tight, slow corners
Juddering or hopping of the rear end when maneuvering
Whining or humming from the rear differential at speed
All-wheel-drive or traction warning messages on the dash
Car behaves as front-wheel drive only (no rear drive engagement)
How to Fix
Preventive care is the cheap fix: change the Haldex oil (and clean the pump screen) every 40,000-60,000 km even though Opel does not require it, and have the diff to Haldex shaft seal checked for weeping whenever the car is on a lift. If knocking/juddering in tight corners has started, have the Haldex pump, fluid condition and seal inspected before the differential is damaged — a pump and oil service is a few hundred euros, while a worn-out unit means a ~2,000 EUR differential or ~4,000 EUR complete rear drive unit. After repair, the Haldex/ABS-ESP software may need reprogramming.
What you need to fix it
Only diagnosis- and fitment-reviewed repair parts are linked here.
BorgWarner 20986573 Saab/Opel coupling oil and filter kit
Confirm Insignia A 4x4/eLSD configuration and keep coupling fluid separate from differential gear oil.
Insignia A front exhaust flex section cracks/fractures around 80,000-150,000 km, especially on diesels. Produces loud rattling/blowing under acceleration, smell of fumes in cabin, and triggers a fault if the lambda sensor is downstream of the leak.
Common Symptoms
exhaust rattle under load
loud blowing noise
fumes in cabin
EML
How to Fix
Flex section can be cut out and replaced (independent specialist €120-€280) instead of buying the full front pipe. OEM full pipe €350-€600. Check downstream lambda sensor function after repair.
What you need to fix it
Only diagnosis- and fitment-reviewed repair parts are linked here.
BM50495 front exhaust flexi pipe for A20DTJ Insignia 2.0 CDTi
Confirm body, drive layout, engine code, OE/front-pipe number and dimensions; not approved for 2.0 Turbo petrol.
The Insignia A uses a cable-pull electric parking brake whose central actuator motor and control electronics are a recurring failure point documented across German Opel forums since the car was new. Owners report the 'Check parking brake' / 'Fehler Parkbremse' warning appearing from as little as ~48,000 km, the EPB refusing to release (dragging rear wheels, car immobilized) or failing to clamp so the car rolls on a slope, and the dash switch going dead. The actuator motor (GM part 13582928) can run to full extension and jam if brake service is done without putting the system in service mode, and repeated repairs are documented — including cases where a replaced actuator failed again. Dealer replacement of the EPB control unit/actuator has been quoted at 1,500-2,000 EUR in forum reports; cheaper causes include a worn EPB switch or corroded/seized brake cables.
Common Symptoms
'Check parking brake' warning message on the instrument cluster
Parking brake will not release — rear wheels dragging or car immobilized
Parking brake fails to hold and the car rolls on a slope
Actuator motor whirs audibly but the brake does not engage
Parking brake switch unresponsive
How to Fix
Diagnose before replacing parts: read EPB fault codes and check the switch, cables and actuator individually — a corroded cable set or worn switch is far cheaper than the actuator/control unit. Always put the EPB into service mode (or use a diagnostic tester) before doing any rear brake work, otherwise the actuator can over-travel and jam. If the actuator motor or control module has failed, replacement (often with the latest software) is the fix; budget a few hundred euros for switch/cables up to 1,500-2,000 EUR for the dealer actuator/control-unit job. Freeing a stuck brake at the roadside may require manual release and a tow.
What you need to fix it
Only diagnosis- and fitment-reviewed repair parts are linked here.
Genuine GM 13271123 black electric parking-brake switch
Confirm connector, colour, VIN and chassis break; later 9060790 and brown 13271124 are different branches.
Both Insignia generations suffer well-documented infotainment failures. On the Insignia A (Navi 900, with and without IntelliLink) owners report the display freezing, going black, the radio muting mid-drive and the unit endlessly rebooting; fault code U150F (internal hardware error) is reported with total loss of all infotainment functions. On the Insignia B (Navi 900 IntelliLink / R 4.0 touch units, 2017 onward) the touch display fails partially or completely — flickering, half-image, unresponsive touch, black screen with 'No audio' shown in the cluster. The failure volume is large enough that specialist German electronics workshops (Endera, kfzpix, Pixelfehler-Reparatur) offer dedicated fixed-price Insignia display/head-unit repair services (~299 EUR), far below the cost of a dealer replacement unit.
Common Symptoms
Screen goes black or freezes while driving
Radio mutes by itself; cluster shows 'No audio'
Touchscreen stops responding to input
System restarts or cycles on and off repeatedly
Display flickers or shows only half the image
How to Fix
First try a soft reset (some freezes clear after disconnecting the battery for ~10 minutes) and ask the dealer to load the latest firmware, which resolved some crash patterns. For hardware faults — flickering, dead touch layer, U150F, reboot loops — the cost-effective route is a board-level repair of the display/head unit by an electronics specialist (around 300 EUR, typically 2-4 hours or mail-in) rather than a new unit from Opel, which can run 800-1,500 EUR plus programming. Check connector seating on the display ribbon cables when the unit is out, as poor connections mimic display failure.
According to Au7o's research across NHTSA recalls, manufacturer TSBs, and owner forum reports, the 2008-2022 Opel Insignia has 8 documented issues. The most frequently reported are: Insignia A 2.0 CDTI Premature Timing Belt / Water Pump Failure (Engine Destruction), Insignia B 2.0 Diesel Fuel Line Chafing — Fire Risk (KBA Recall E191905110 / 20-C-012), Insignia A 2.0 CDTI EGR Cooler Crack (Coolant Loss into Intake). Of these, 5 are rated critical and should be addressed promptly.
Is the Opel Insignia reliable?
The 2008-2022 Opel Insignia has 8 known issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports. 5 issues are rated critical: Insignia A 2.0 CDTI Premature Timing Belt / Water Pump Failure (Engine Destruction) and Insignia B 2.0 Diesel Fuel Line Chafing — Fire Risk (KBA Recall E191905110 / 20-C-012) and Insignia A 2.0 CDTI EGR Cooler Crack (Coolant Loss into Intake) and Insignia A Aisin AF40 Harsh Shifts / Shudder and Insignia A 4x4 Haldex Coupling & Rear Differential Failure (Oil Mixing / Pump Failure). Prospective buyers should inspect for these issues and factor potential repair costs into their purchase decision. Regular maintenance following the manufacturer's schedule helps prevent many common problems.
How much does it cost to fix common Opel Insignia problems?
Repair costs for known Opel Insignia issues range from $0 to $6,500, depending on the specific problem and whether you choose DIY or professional repair. The most critical issue, Insignia A 2.0 CDTI Premature Timing Belt / Water Pump Failure (Engine Destruction), typically costs $550-$6,500 to repair. Au7o provides step-by-step DIY maintenance guides that can help reduce repair costs.
What year Opel Insignia is the most reliable?
Reliability varies across model years of the Opel Insignia. Based on documented issues, problems are most commonly reported in earlier model years. Au7o recommends checking the specific known issues for your target year before purchasing, and having a pre-purchase inspection performed by a qualified mechanic. Our known issues database covers the 2008-2022 Opel Insignia with 8 documented issues compiled from NHTSA recalls, manufacturer TSBs, and owner forum reports.
Content on this page was compiled with AI assistance using NHTSA complaints, TSBs, owner reports, and public automotive data. While we strive for accuracy, this information may contain errors. Always verify repair procedures and specifications with your vehicle's service manual or a qualified mechanic.
What is the 2009-2017 Opel Insignia Insignia A 2.0 CDTI Premature Timing Belt / Water Pump Failure (Engine Destruction)?
The 2.0 CDTI diesel (A20DTH/A20DTJ) in the Insignia A uses a timing belt on an interference engine, and German and UK owner communities document repeated belt failures well before the official 120,000-150,000 km / 10-year change interval. A common trigger is the belt-driven water… Repairs typically run $550-$6,500. Severity: high.
What is the 2017-2019 Opel Insignia Insignia B 2.0 Diesel Fuel Line Chafing — Fire Risk (KBA Recall E191905110 / 20-C-012)?
Official KBA-supervised recall: on Insignia B models with the 2.0-liter diesel built between July 2016 and November 2018, a faulty clamp/bracket can rub through the fuel line. Leaking diesel can reach hot engine components and cause an engine-bay fire. Roughly 45,000 vehicles wer… Repairs typically run $0-$0. Severity: high.
What is the 2008-2015 Opel Insignia Insignia A 2.0 CDTI EGR Cooler Crack (Coolant Loss into Intake)?
The A20DT/A20DTH 2.0 CDTI EGR cooler develops internal cracks, allowing coolant to leak into the intake. Symptoms: white smoke from exhaust, mysterious coolant loss with no external leak, sweet smell, eventual no-start as cylinders flood. Common at 100,000-180,000 km. Same engine… Repairs typically run $600-$1,800. Severity: high.
What is the 2008-2017 Opel Insignia Insignia A Aisin AF40 Harsh Shifts / Shudder?
The Aisin AF40 6-speed automatic in Insignia A (2008-2017) develops harsh shifts, shudder during lock-up, and delayed engagement, typically by 100,000-160,000 km. Root cause is degraded ATF and worn solenoids; Opel's "lifetime fill" claim is widely disputed. Repairs typically run $150-$2,500. Severity: high.
What is the 2009-2017 Opel Insignia Insignia A 4x4 Haldex Coupling & Rear Differential Failure (Oil Mixing / Pump Failure)?
Insignia A 4x4 models (including the OPC) suffer chronic failures of the rear drive unit: the shaft seal (Simmerring) between the rear differential and the Haldex coupling degrades, letting the two separate oil fills mix into sludge, while the Haldex hydraulic pump fails from con… Repairs typically run $800-$4,500. Severity: high.
What is the 2008-2017 Opel Insignia Insignia A Flex-Pipe Exhaust Failure?
Insignia A front exhaust flex section cracks/fractures around 80,000-150,000 km, especially on diesels. Produces loud rattling/blowing under acceleration, smell of fumes in cabin, and triggers a fault if the lambda sensor is downstream of the leak. Repairs typically run $120-$600. Severity: medium.
What is the 2009-2017 Opel Insignia Insignia A Electric Parking Brake Actuator / Control Module Failure?
The Insignia A uses a cable-pull electric parking brake whose central actuator motor and control electronics are a recurring failure point documented across German Opel forums since the car was new. Owners report the 'Check parking brake' / 'Fehler Parkbremse' warning appearing f… Repairs typically run $300-$2,200. Severity: medium.
What is the 2012-2022 Opel Insignia Navi 900 / IntelliLink Infotainment Display Failure (Black Screen, Freezing, Reboot Loops)?
Both Insignia generations suffer well-documented infotainment failures. On the Insignia A (Navi 900, with and without IntelliLink) owners report the display freezing, going black, the radio muting mid-drive and the unit endlessly rebooting; fault code U150F (internal hardware err… Repairs typically run $330-$1,600. Severity: medium.
