N232413960 Service Bulletin/Repair Instructions

Customer Satisfaction Program

N232413960 Vehicles Built Without Passenger Seats

Release Date:

Attention:
November 2023
Revision:
00
This field action can only be completed by BrightDrop dealers or BrightDrop certified repair facilities

who have met all BrightDrop specific training, tool and equipment requirements. Repairs must be

performed by a technician who has successfully completed the required training.

This program is in effect until December 31, 2025.
Make

BrightDrop
Model

Zevo 600
Model Year

From

To

2023

2023
RPO
Description
Involved vehicles are marked “Open” on the Investigate Vehicle History screen in GM Global Warranty Management

system. This site should always be checked to confirm vehicle involvement prior to beginning any required inspections

and/or repairs.

Condition

Correction
Certain 2023 model year BrightDrop Zevo 600 vehicles may have been built without the passenger

side jump seat.

Dealers are to install the passenger side jump seat.
Parts

Quantity

9

13

1

1

1

1

1

1

1

2

1

1

1

1

11

1

1

1

4

1

1

1

1
Part Name

Pan Head Screws

Headliner Retainer

Windshield Sensor Cover

Seat back bracket

Seat back bracket

Bolt

Cushion Assembly

Seat Back Assm

Hip Blocker Assm

M8 Nuts

Passenger Roof Rail Airbag

Passenger Seat Belt and Retractor

Tire Pressure Label (with Occupancy info) (VIN Specific)

B-Pillar Trim

Rivets

New Frame Stand -off

Doubler Plate

Bolster airbag

Bolt

Front Lower Extruded Trim Piece

Front side door lower trim panel

Headrest bolt

Delfleet Evolution F4921BK or DP90LF
Part No.

11611317

13475541

85127617

85597882

85597881

11561031

85037819

85037817

85037821

11546365

85016097

87830275

15261447

85016234

11604983

85035516

85035517

85039688

11609341

85635952

85661518

11546465

Obtain Locally
Reminder: Parts may be removed from Retail Inventory Management (RIM). Dealers should review the affected parts

to confirm RIM managed status. Parts may have quantity limiters in effect.

Please follow normal ordering processes utilizing BrightDrop Connect. Please contact [email protected] for

any parts ordering questions.

Warranty Information

Labor

Operation

9107077
Description

Install Passengers Side Jump Seat (Including necessary body

structure modifications and Restraint Control Module programming)
Labor

Time

3.8
Trans.

Type

ZFAT
Net

Item

N/A
Important: (TECHNICIAN and WARRANTY ADMINISTRATOR) SERIAL NUMBER RECORDING REQUIREMENT. The

replacement and old roof rail and bolster airbag serial numbers must be captured by the technician and recorded on

the job card. The Warranty Administrator MUST enter the serial numbers in GWM (Global Warranty Management) or

in DMS (Dealer Management System). Enter the serial number of one replacement airbag in the ‘Labor Operation

Copyright 2023 General Motors. All Rights Reserved.
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Customer Satisfaction Program

N232413960 Vehicles Built Without Passenger Seats

Dependency Code’ field per the screen shown. Enter the old serial numbers and the other new serial number in the

comments section, indicating which is which.
5844317
Service Procedure

Important: Service agents must comply with all International, Federal, State, Provincial, and/or Local laws

applicable to the activities it performs under this bulletin, including but not limited to handling, deploying,

preparing, classifying, packaging, marking, labeling, and shipping dangerous goods. In the event of a conflict

between the procedures set forth in this bulletin and the laws that apply to your dealership, you must follow

those applicable laws.

Warning: Unless directed otherwise, the ignition must be OFF with the key removed, and all electrical loads

must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an

electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to

follow these precautions may result in personal injury and/or damage to the vehicle or its components.

For Vehicles equipped with OnStar® (UE1) with Back Up Battery:

The Back Up Battery is a redundant power supply to allow limited OnStar® functionality in the event of a main

vehicle battery power disruption to the VCIM (OnStar®module). Do not disconnect the main vehicle battery or

remove the OnStar® fuse with the ignition key in any position other than OFF. Retained accessory power

should be allowed to time out or be disabled (simply opening the driver door should disable retained accessory

power) before disconnecting power. Disconnecting power to the OnStar® module in any way while the ignition

is On or with retained accessory power activated may cause activation of the OnStar® Back-Up Battery system

and will discharge and permanently damage the back-up battery. Once the Back-Up Battery is activated it will

stay on until it has completely discharged. The back-up battery is not rechargeable and once activated the

back-up battery must be replaced.

Caution: This vehicle is equipped with a High Voltage (HV) battery safety monitoring system. The HV battery

monitoring and notification system is disabled when the 12 Volt battery/system is removed/disconnected. To minimize

the risk associated with a disabled HV battery safety monitoring system, always observe the following:

• Only disconnect the 12V battery/system as indicated by a service procedure.

• Minimize the length of time the 12V battery/system is disabled.

• Minimize the length of time the vehicle is left in a disassembled condition.

Note: The battery monitor module is attached directly to the battery negative terminal. It determines the battery

condition by calculating the battery state of charge (SOC), functions, and state of health, which is used to help

determine if the 12V Stop/Start system will allow an auto stop when the vehicle has come to a stop. IF only

disconnecting the battery negative cable, do NOT disconnect the battery monitor module electrical connector at the

module and do NOT disconnect the module at the battery negative post or else a module learn will be required to

calibrate the module.

1.

2.

3.

4.

5.
Apply parking brake.

Ensure the vehicle is turned off.

Check if the vehicle is plugged in to charge, and if so, disconnect it from the charger.

Mix paint per instructions provided with the F4921BK or DP90LF paint (on the can or on Technical Data Sheet

provided with the product).

Using prep wipes, thoroughly clean all provided rivets.

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Customer Satisfaction Program

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5901951

6.

7.
8.

9.
Front Floor Auxiliary Mat Retainer (1) » Remove [5x]

Front Floor Auxiliary Mat (2) » Remove
6255445

Turn each dash lower center extension panel bolt (1) approximately one quarter turn and pull the bolt outwards

lightly to disengage the bolt at the retainer.

Dash Lower Center Extension Panel - Upper (2) » Remove
Warning: Always ensure the Battery Maintenance Mode is inactive before disconnecting the 12 volt battery.

This mode can be active with the ignition off, regardless of whether the vehicle charging cord is plugged in or

not. When this mode is active, the on-board high voltage battery charger will energize the 12 volt battery cables

and charge the 12 volt battery. Disconnecting the battery cables while this mode is active may result in an

electrical shock or a burn from hot battery cable leads.

Warning: Unless directed otherwise, the ignition must be OFF with the key removed, and all electrical loads

must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an

Page 3 of 41
Customer Satisfaction Program

N232413960 Vehicles Built Without Passenger Seats

electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to

follow these precautions may result in personal injury and/or damage to the vehicle or its components.

For Vehicles equipped with OnStar® (UE1) with Back Up Battery:

The Back Up Battery is a redundant power supply to allow limited OnStar® functionality in the event of a main

vehicle battery power disruption to the VCIM (OnStar®module). Do not disconnect the main vehicle battery or

remove the OnStar® fuse with the ignition key in any position other than OFF. Retained accessory power

should be allowed to time out or be disabled (simply opening the driver door should disable retained accessory

power) before disconnecting power. Disconnecting power to the OnStar® module in any way while the ignition

is On or with retained accessory power activated may cause activation of the OnStar® Back-Up Battery system

and will discharge and permanently damage the back-up battery. Once the Back-Up Battery is activated it will

stay on until it has completely discharged. The back-up battery is not rechargeable and once activated the

back-up battery must be replaced.

Caution: This vehicle is equipped with a High Voltage (HV) battery safety monitoring system. The HV battery

monitoring and notification system is disabled when the 12 Volt battery/system is removed/disconnected. To minimize

the risk associated with a disabled HV battery safety monitoring system, always observe the following:

• Only disconnect the 12V battery/system as indicated by a service procedure.

• Minimize the length of time the 12V battery/system is disabled.

• Minimize the length of time the vehicle is left in a disassembled condition.

Note: The battery monitor module is attached directly to the battery negative terminal. It determines the battery

condition by calculating the battery state of charge (SOC), functions, and state of health, which is used to help

determine if the 12V Stop/Start system will allow an auto stop when the vehicle has come to a stop. IF only

disconnecting the battery negative cable, do NOT disconnect the battery monitor module electrical connector at the

module and do NOT disconnect the module at the battery negative post or else a module learn will be required to

calibrate the module.

10. Check the 12 volt battery voltage with a digital multimeter before disconnecting any battery cables leads. If the

voltage is 13.5 volts or above, the Battery Maintenance Mode is active. The technician must wait for the T18 battery

charger to deactivate before disconnecting the battery negative cable. Refer to Charging System Description and

Operation for more information.
5911766

11. Engage the high voltage service lockout (HVSL) (1) by lifting the red connector position assurance tab, then while

depressing the connector tab, pull apart the connector halves until the indicator tab wording changes from ON to

OFF. Place a tie strap or a high voltage disable padlock through the exposed HVSL hole to prevent improper reengagement.
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Customer Satisfaction Program

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6302625

12. Battery Negative Cable Nut (1) » Remove

13. Battery Negative Cable (2) @ Battery Monitor Module » Reposition away

14. Place the front side passenger door in the full open position.
5880865

15. Remove the 4 Front Side Door Inner Guide Bolts (1)
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Customer Satisfaction Program

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5880862

16. Remove the Front Side Door Inner Guide (1)
5880896

17. Remove the 4 Front Side Door Guide Bolt (1)
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Customer Satisfaction Program

N232413960 Vehicles Built Without Passenger Seats
5880896

18. Remove the Front Side Door Guide (1)
5880881

19. Remove and discard the 4 Front Side Door Guide Molding Bolt (1)
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Customer Satisfaction Program

N232413960 Vehicles Built Without Passenger Seats
5880947

20. Remove and DISCARD the Front Side Door Guide Molding (1).

21. Using a Floor Jack, lift and support the vehicle.

Caution: When you are jacking the vehicle at the front locations, be certain that the jack or the jack lift pad does not

contact the front fascia, front fascia air dam, or the front fenders. If such contact occurs, vehicle damage may result.

When jacking at selected front locations additional clearance may be required for the jacking points. When you are

lifting a vehicle with a service floor jack, block the wheels at the opposite end from which you are lifting. Use jack stands

to provide additional support. Be sure to place a block pad between the service floor jack lift surface and the vehicle or

utilize an integrated jack with pad to prevent underbody damage.The service floor jack pad interface must not cause

damage to the vehicle underbody, such as weld flanges, shields, the battery pack, lower control arms, springs. The

service floor jack pad must not contact the rocker panel or the floor pan.

Note:

• When you are lifting a vehicle with a service floor jack, block the wheels at the opposite end from which you are

lifting. Use jack stands to provide additional support.

• Be sure to place a block pad between the service floor jack lift surface and the vehicle or utilize an integrated jack

with pad to prevent underbody damage.

• The service floor jack pad interface must not cause damage to the vehicle underbody, such as weld flanges, shields,

the battery pack, lower control arms, springs.

• The service floor jack pad must not contact the rocker panel or the floor pan.
Page 8 of 41
Customer Satisfaction Program

N232413960 Vehicles Built Without Passenger Seats
5990972

Note: ONLY lift the forward portion of the bracket. Do NOT lift the rear of the bracket.

22. When lifting the Front of the vehicle with a service floor jack, lift the vehicle at the front lift pad (1) on the

passenger’s side only. Place jack stand under the secondary jacking location on the passenger side to provide

additional support (2).

Note: ONLY lift the forward portion of the bracket. Do NOT lift the rear of the bracket. It is only necessary to lift the

passenger’s front corner of the vehicle for this procedure.

23. When supporting the Front of the vehicle with service jack stands only, support the vehicle at the primary service

floor jack location (1). Utilize the secondary service floor jack location (2) to lift the front of the vehicle to then place

the service jack stands.
5837777

24. Remove the Front Wheelhouse Liner Bolt (2)

25. Remove and DISCARD the Rear Body Side Paint Protector. Apply a double layer of masking tape around the

perimeter of the painted surfaces.
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Customer Satisfaction Program

N232413960 Vehicles Built Without Passenger Seats
6411251
26. Insert Template A pins into sill plate holes and mark with a center punch and then remove template.

27. Drill and deburr a hole 9.5mm (3/8 inch) at template center hole.

28. Install new front bracket behind newly drilled hole.
6411255
29. Locate front bracket assembly using the drilled hole and secure with bolt (hand tight).
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Customer Satisfaction Program

N232413960 Vehicles Built Without Passenger Seats
6411269
30. With bracket secure in place (bolt hand tight) drill and deburr hole in green rail using front hole (6.7mm 17/64 in)

using bracket as template.

31. Prepare a rivet by fully submerging it the previously mentioned Paint/Corrosion material and insert rivet into hole.
6411271
Important: Rivet MUST fully be submerged and coated in product to prevent any corrosion.

32. Install prepared rivet into newly drilled hole.

33. Then drill and deburr hole in green rail using bracket rear hole and insert 2nd prepared rivet in rear hole.
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Customer Satisfaction Program

N232413960 Vehicles Built Without Passenger Seats
6431341
34. Position doubler plate to the bracket rearward of the newly installed bracket like illustrated above and secure with

vice grips. Ensure doubler plate is perfectly flush with the bottom of the bracket, and use Template A as a spacer as

shown to space it out from the outside of the vehicle.
6411276
35.

36.

37.

38.

39.

40.
Drill a 6.7mm (17/64 in) hole in the inboard location (A).

Install rivet (GM part number 11604983).

Drill a 6.7mm (17/64 in) hole in the middle location (B).

Install rivet (GM part number 11604983).

Drill a 6.7mm (17/64 in) hole in the outboard location (C).

Install rivet (GM part number 11604983).
Page 12 of 41
Customer Satisfaction Program

N232413960 Vehicles Built Without Passenger Seats
6431351
41. Remove the two Front Side Door Lower Guide bolts indicated by tape above, align & insert Template B pins into

guide holes & sill plate nuts.
6411290
42. Use one of the removed Front Side Door Lower Guide bolt to tighten Template B into place (finger tight).
Page 13 of 41
Customer Satisfaction Program

N232413960 Vehicles Built Without Passenger Seats
6411291
43. Drill 6 ¼ inch holes using Template B guide holes from the top down (holes must go through the guide, the sill plate

and bracket). Remove Template B from the vehicle.

44. Redrill the ¼ inch holes using a 6.7mm (17/64ths) drill and then deburr all drilled holes.
6411295
45. Illustration shows sill and guide with both sets of holes.
Page 14 of 41
Customer Satisfaction Program

N232413960 Vehicles Built Without Passenger Seats
6411607

46. Insert Drill Protector (steel) between sill plate and lower guide and align template clearance holes.
6411610

47. Using hole saw (approx. 28.5mm diam. With smooth guide pin) and the pilot holes as locator, drill six clearance

holes. Drill through to the lower plastic guide until contact with the steel spacer.
Page 15 of 41
Customer Satisfaction Program

N232413960 Vehicles Built Without Passenger Seats
6411612

Lower guide with clearance holes drilled out.

48. Remove Drill Protector.
6411613

49. Using rivet gun install and secure 6 rivets.

50. Once rivets are installed, paint all the newly installed rivets with the previous mentioned corrosion protection coating

on both top and bottom.

51. Torque the outside bolt to 16 ft-lbs (22Nm)

52. Reinstall the Front Side Door Lower Guide bolts into the vehicle and torque to 80 lb in (9 N-m).
Page 16 of 41
Customer Satisfaction Program

N232413960 Vehicles Built Without Passenger Seats
5837777

53.

54.

55.

56.

57.
Install New Rear Body Side Paint Protector.

Install Front Wheelhouse Liner Bolt (2).

Torque to 2.5 Nm (22 lb in).

Lower vehicle.

Remove the double layer of masking tape around the perimeter of the painted surfaces.
5880881

58. Install a NEW Front Side Door Guide Molding (1).
Page 17 of 41
Customer Satisfaction Program

N232413960 Vehicles Built Without Passenger Seats
5880943

59. Install new Front Side Door Guide Molding Bolts (1).

60. Install New and tighten to 9 Nm (80 lb in).
5880881

61. Install Front Side Door Guide (1)
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Customer Satisfaction Program

N232413960 Vehicles Built Without Passenger Seats
5880896

62. Install Front Side Door Guide Bolts (1)

63. Tighten to 9 Nm (80 lb in).
5880862

64. Install Front Side Door Inner Guide (1).
Page 19 of 41
Customer Satisfaction Program

N232413960 Vehicles Built Without Passenger Seats
5880865

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