The data is sent to the central engine control system, which accordingly adjusts the volume and timing of the fuel injections. This closed loop system ensures the engine always operates with optimum efficiency and minimal exhaust emissions. Over the entire lifecycle of the Insignia, it compensates for wear factors such as inaccuracies in the fuel metering, component tolerances, varying fuel qualities and operating conditions.

The Insignia ecoFLEX accelerates from zero to 100 kph in 9.5 seconds and reaches a top speed of up to 218 kph (135 mph). The maximum torque of 350 Nm is available from 1,750 rpm, and can be temporarily increased for 15 seconds to 380 Nm via an ‘overboost’ function.

The regular Insignia has a drag factor of 0.27; Insignia ecoFLEX drops that down to 0.26. The low coefficient of drag results in less engine power required to overcome air resistance than smaller cars. This is key, Opel says, because when doubling speed, the power necessary to overcome aerodynamic drag increases by a factor of eight. For example, if 2 kW are necessary to overcome aerodynamic drag at 60 kph, 16 kW are needed at 120 kph.

Opel optimized the Insignia ecoFLEX aerodynamics in many areas using traditional methods like adding paneling under the tank in front of the rear axle, which improves drag coefficient and increases downforce. They also lowered the body by 10 mm to reduce the frontal area and partially closed the radiator grille to send more head wind around the body for better aerodynamics.

Compared to the predecessor, the Insignia’s wingshaped exterior mirrors create 45% less aerodynamic drag. During numerous computer simulations and more than 650 hours in the wind tunnel, numerous other details were fine-tuned for even better aerodynamic performance, including adding a flexible front spoiler lip, rounding front bumper corners, slightly changing the windshield wiper position, rounding the A-pillar, ensuring roof air flows without separating, integrating the rear spoiler lip, integrating a separation edge into the tail lights, separating the edge on the rear bumper, optimizing the shape of the lower control arm in the rear suspension and adding a spoiler edge at end of door sill in front of rear wheels and wheel caps.

In the process, many of these modifications also benefited the Insignia’s aeroacoustics, resulting in an interior cabin that is quieter than any Opel ever before. Engineers already focused on noise reduction during initial development, taking a new road at this early stage: A completed 1:1-scale clay model was used for noise measurement. The new Insignia also has additional door sealing compared to past models. The side windows’ thickness was increased to 4.85 mm, further contributing to the low noise level in the interior compartment.

The Insignia ecoFLEX is fitted with fuel-efficient Primacy HP tires from Michelin specially developed for the car. Like all Insignia models, the new ecoFLEX variant is Euro 5 certified and will be available as a hatchback and notchback during the course of 2009. The Insignia ecoFLEX will be marketed in the UK under the Vauxhall marque.

The Insignia ecoFLEX joints ecoFLEX models from the Astra and Corsa lines. The Opel Corsa 1.3 CDTI ecoFLEX consumer 4.1 liters of diesel per 100 km (57.4 mpg US), emitting 109 g/km CO₂. The Astra 1.7 CDTI ecoFLEX requires 4.5 liters of diesel per 100 km (52 mpg US) and releases 119 g/km CO₂. Both cars are fitted with a maintenance-free diesel particulate filter as standard.