13296A Service Bulletin/Repair Instructions

Bulletin No.: 13296A

Date: November 2013
Recall Bulletin
PRODUCT SAFETY RECALL

SUBJECT:
Insufficient Weld on Front Fuel Tank Strap Bracket
MODELS:
2013-2014 Chevrolet Sonic
This bulletin has been revised to include a copy of the customer letter. Please discard

all copies of bulletin 13296.

All involved vehicles that are in dealer inventory must be held and not delivered to

customers, dealer traded, or used for demonstration purposes until the repair contained

in this bulletin has been performed on the vehicle.

CONDITION

General Motors has decided that a defect, which relates to motor vehicle safety, exists in

certain 2013-2014 model year Chevrolet Sonic vehicles. A front fuel tank strap bracket may

separate from the vehicle due to insufficient welds. If this occurs, the increased load on the

remaining bracket could cause it to separate. The fuel tank would not be supported by the

fuel tank straps and would rest on the exhaust pipe and/or the plastic fuel tank shield. If this

occurs, the occupants may hear a rattling or scraping noise. If the fuel tank shield and fuel

filler neck do not support the fuel tank, the fuel tank may separate from the vehicle. If the fuel

tank is punctured, and if a source of ignition is present, a fire could occur.

CORRECTION,

Dealers are to inspect the front fuel tank strap bracket welds. If the welds are smaller than

specified, dealers are to install rivets to secure the bracket.

VEHICLES INVOLVED

All involved vehicles are identified by Vehicle Identification Number on the Investigate Vehicle

History screen in GM Global Warranty Management system. Dealership service personnel

should always check this site to confirm vehicle involvement prior to beginning any required

inspections and/or repairs. It is important to routinely use this tool to verify eligibility because

not all similar vehicles may be involved regardless of description or option content.

For dealers with involved vehicles, a listing with involved vehicles containing the complete

vehicle identification number, customer name, and address information has been prepared

and will be provided to dealers through the GM GlobalConnect Recall Reports. Dealers will

not have a report available if they have no involved vehicles currently assigned.

Copyright 2013 General Motors. All Rights Reserved.
Page 2
November 2013
Bulletin No.: 13296A
The listing may contain customer names and addresses obtained from Motor Vehicle

Registration Records. The use of such motor vehicle registration data for any purpose other

than follow-up necessary to complete this recall is a violation of law in several

states/provinces/countries. Accordingly, you are urged to limit the use of this report to the

follow-up necessary to complete this recall.

PART INFORMATION

Note: It is estimated that less than 12 vehicles will require bracket repair.

If the inspection determines that the welds need repair, the parts listed below will be required.

The rivets and RTV sealant are to be obtained from General Motors Customer Care and

Aftersales (GMCC&A). Normal orders should be placed on a DRO = Daily Replenishment

Order. In an emergency situation, parts should be ordered on a CSO = Customer Special

Order.

The drill bits and Ashland Pliogrip are to be ordered as indicated.

Part Number

11569698

88861417 – US

88861418 - CN
Description

RIVET
Quantity/Vehicle

16
SEALANT, RTV
1
Obtain Locally
1/8" (3.17 MM) COBALT DRILL BIT
Obtain Locally
17/64" (6.75 MM) COBALT DRILL BIT
7770B220*
ASHLAND PLIOGRIP (ADHESIVE)
2

(submit as Net Item)

2

(submit as Net Item)

1

(Submit as Net Item)
* Ashland Pliogrip is to be obtained from Crest Industries, Inc. as follows:

U.S. Dealers: Call 1-800-822-4100, 8:00 AM – 4:30 PM EST

Canadian Dealers: Call J-2 Products (Crest Distributor) at 1-888-880-0025 or 416-665-1404

(Canada), 8:00 AM – 4:30 PM EST.

Note: Depending on availability, Ashland Pliogrip (Green), part number 7770/220, may be

provided in place of the black version of the Ashland Pliogrip, part number 7770B/220. A dual

cartridge applicator tool is required to apply the Pliogrip two-part polyurethane adhesive. If

your dealership does NOT have a dual cartridge applicator tool, obtain one from Crest

Industries.

SERVICE PROCEDURE

Fuel Tank Bracket Weld Inspection

Note: A chisel and hammer are required to complete the fuel tank bracket weld inspection.

1.
Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle in SI.
Page 3
November 2013
Bulletin No.: 13296A
3639561
Arrow indicates direction for front of vehicle. (1) Fuel Tank Strap Bracket locations. (2) Fuel Tank.
2.
Locate the front fuel tank strap brackets (1).
3639571
Note: Ensure the chisel is positioned between the bracket and the vehicle floor pan. Firmly

strike the chisel three (3) times to determine if there is a good weld between the bracket and

floor pan. Perform the fuel tank bracket repair in this bulletin if one or both of the fuel

tank strap brackets fully OR partially separate from the floor pan after performing the

inspection.

3.
Using a chisel and a hammer, inspect the welds of the front driver and passenger side fuel

tank strap brackets (3). Refer to portion ‘D’ of the photograph to view the driver side fuel

tank strap bracket. Refer to portion ‘P” of the photograph to view the passenger side

bracket.

 If the two fuel tank strap brackets do NOT separate from the floor pan after performing

the chisel test, lower the vehicle. Refer to Lifting and Jacking the Vehicle in SI. No

further action is required.
Page 4
November 2013
Bulletin No.: 13296A
 If either of the fuel tank strap brackets separate from the floor pan after performing the

chisel test, the fuel tank strap brackets MUST be repaired. Refer to Fuel Tank Bracket

Repair in this bulletin.

Fuel Tank Bracket Repair

Note: The following tools are required to complete the service procedure in this bulletin:

 A compact quality drill.

 Drill bits that will drill through high strength steel.


A pneumatically powered pop rivet gun that accepts 6.35 mm (¼ in), 4.76 mm (3/16 in),

3.96 mm (5/32 in) and 3.17 mm (1/8 in) rivets.
 Small disposable brush for spreading the Pliogrip two-part polyurethane.

1.
Remove the fuel tank from the vehicle. Refer to Fuel Tank Replacement in SI.
2.
Make a pop rivet template tool using one of the rivets and a punch.
3639576
2.1 Insert a pop rivet into the pop rivet gun.

2.2 Eject pop rivet into tool box drawer as shown in illustration.
3639582
2.3 Collect the pop rivet head from the tool box drawer.
Page 5
November 2013
Bulletin No.: 13296A
3639585
Warning: The rivet head will get hot during the hole drilling process. Use pliers to

remove the pop rivet from the vice. Allow the pop rivet head to cool BEFORE

assembling the pop rivet template tool.

2.4 Secure the pop rivet head into a vice.

2.5 Drill a pilot hole through the center of the pop rivet head using a 3.17 mm (1/8 in) bit.

Begin drilling from the stem side of the pop rivet head first (1).

2.6 Drill 6.75mm (17/64 in) hole through the pilot hole (2) (3).
3639588
2.7 Insert the point (1) of the punch (2) through the hole in the rivet head.

3.
Determine the condition of the fuel tank strap bracket.
Page 6
November 2013
Bulletin No.: 13296A
Caution: Ensure the Pliogrip two-part polyurethane mix is uniform in color BEFORE

applying it to the backside of the fuel tank strap bracket. Discard the first 25 mm (1 in)

of the mix that is not uniform. The color of the polyurethane varies: The polyurethane

mix will be either black or green. The Pliogrip two-part polyurethane has a 30-minute

open time. The application of the Pliogrip two-part polyurethane and the assembly of

the driver and passenger side fuel tank strap brackets must be completed in 30

minutes.

Note: Use duct tape to secure the fuel tank strap bracket to the floor pan. Locate the fuel tank

strap bracket in its original position. Look for witness marks on the floor pan to assist in

locating the proper location for the bracket.


If the fuel tank strap bracket fell off during the weld inspection, apply the Pliogrip twopart polyurethane, P/N 7770B220, to the backside of the bracket using a small brush.

Ensure the Pliogrip is applied to the backside of the fuel tank strap bracket mounting

tabs. The mounting tabs contact the floor pan of the vehicle.
Caution: To avoid damaging the fuel tank strap bracket, do NOT attempt to pry the fuel

tank strap bracket off the floor pan if the bracket is ONLY partially separated from the

floor pan.


If the fuel tank strap bracket is only partially separated from the floor pan, apply the

Pliogrip two-part polyurethane, P/N 7770B220, with a small brush to the backside of

bracket where it is separated from the floor pan.
3639591
Note: Use the pop rivet head on pop rivet tool as guide to ensure proper clearance is achieved

between tab portion of the bracket and the raised portion of the bracket.

4.
Using the pop rivet template tool, center punch the bracket metal in the six locations that a

hole will be drilled. Refer to the photographs BEFORE steps 5-10.
Page 7
November 2013
Bulletin No.: 13296A
3639593
5.
Drill six 3mm (1/8 in) pilot holes into the passenger side fuel tank strap bracket.
6.
Drill six 3mm (1/8 in) pilot holes into the driver side fuel tank strap bracket.
3639597
7.
Drill six 6.75mm (17/64 in) holes through the six pilot holes of the passenger side fuel tank

strap bracket.
8.
Drill six 6.75mm (17/64 in) holes through the six pilot holes of the driver side fuel tank

strap bracket.
Page 8
November 2013
Bulletin No.: 13296A
3639598
9.
Install the six pop rivets, P/N 11569698, into the passenger side fuel tank strap bracket.
10. Install the six pop rivets, P/N 11569698, into the driver side fuel tank strap bracket.
3639601
11. Apply RTV, P/N 88861417 (88861418 for Canada) (or equivalent), on and around each of

the 6 rivet heads of the passenger side fuel tank strap bracket.

12. Apply RTV, P/N 88861417 (88861418 for Canada ) (or equivalent), on and around each of

the 6 rivet heads of the driver side fuel tank strap bracket.

13. Install the fuel tank. Refer to Fuel Tank Replacement in SI.
Page 9
November 2013
Bulletin No.: 13296A
COURTESY TRANSPORTATION

The General Motors Courtesy Transportation program is intended to minimize customer

inconvenience when a vehicle requires a repair that is covered by the New Vehicle Limited

Warranties. The availability of courtesy transportation to customers whose vehicles are within

the warranty coverage period and involved in a product program is very important in

maintaining customer satisfaction. Dealers are to ensure that these customers understand

that shuttle service or some other form of courtesy transportation is available and will be

provided at no charge. Dealers should refer to the General Motors Service Policies and

Procedures Manual for Courtesy Transportation guidelines.

WARRANTY TRANSACTION INFORMATION

Submit a transaction using the table below. All transactions should be submitted as a ZFAT

transaction type, unless noted otherwise.

Labor

Code

9100208

9100209

*
Description

Inspect Fuel Tank Strap Bracket – No Further Action

Req'd

Repair Fuel Tank Strap Bracket (inc inspection)
Labor

Time

0.3
Net

Item

N/A
2.5
*
Submit for the actual cost of the drill bits and Ashland Pliogrip needed to perform the

required repairs.
CUSTOMER NOTIFICATION

General Motors will notify customers of this recall on their vehicle (see copy of customer letter

included with this bulletin).

DEALER RECALL RESPONSIBILITY – For US (US States, Territories, and

Possessions)

It is a violation of Federal law for a dealer to deliver a new motor vehicle or any new or used

item of motor vehicle equipment (including a tire) covered by this notification under a sale or

lease until the defect or noncompliance is remedied.

The US National Traffic and Motor Vehicle Safety Act provides that each vehicle that is subject

to a recall of this type must be adequately repaired within a reasonable time after the customer

has tendered it for repair. A failure to repair within sixty days after tender of a vehicle is prima

facie evidence of failure to repair within a reasonable time. If the condition is not adequately

repaired within a reasonable time, the customer may be entitled to an identical or reasonably

equivalent vehicle at no charge or to a refund of the purchase price less a reasonable

allowance for depreciation. To avoid having to provide these burdensome remedies, every

effort must be made to promptly schedule an appointment with each customer and to repair

their vehicle as soon as possible. In the recall notification letters, customers are told how to

contact the US National Highway Traffic Safety Administration if the recall is not completed

within a reasonable time.
Page 10
November 2013
Bulletin No.: 13296A
DEALER RECALL RESPONSIBILITY – All

All unsold new vehicles in dealers' possession and subject to this recall must be held and

inspected/repaired per the service procedure of this recall bulletin before customers take

possession of these vehicles.

Dealers are to service all vehicles subject to this recall at no charge to customers, regardless

of mileage, age of vehicle, or ownership, from this time forward.

Customers who have recently purchased vehicles sold from your vehicle inventory, and for

which there is no customer information indicated on the dealer listing, are to be contacted by

the dealer. Arrangements are to be made to make the required correction according to the

instructions contained in this bulletin. A copy of the customer letter is provided in this bulletin

for your use in contacting customers. Recall follow-up cards should not be used for this

purpose, since the customer may not as yet have received the notification letter.

In summary, whenever a vehicle subject to this recall enters your vehicle inventory, or is in

your dealership for service in the future, you must take the steps necessary to be sure the

recall correction has been made before selling or releasing the vehicle.
GM bulletins are intended for use by professional technicians, NOT a "do-it-yourselfer". They are written to inform these technicians of conditions that

may occur on some vehicles, or to provide information that could assist in the proper service of a vehicle. Properly trained technicians have the tools,

equipment, safety instructions, and know-how to do a job properly and safely. If a condition is described, DO NOT assume that the bulletin applies to

your vehicle, or that your vehicle will have that condition. See your dealer for information on whether your vehicle may benefit from the information.
We Support

Voluntary Technician

Certification
Page 11
November 2013
Bulletin No.: 13296A

November 2013
Dear General Motors Customer:

This notice is sent to you in accordance with the requirements of the National Traffic and

Motor Vehicle Safety Act.

General Motors has decided that a defect, which relates to motor vehicle safety, exists in

certain 2013-2014 model year Chevrolet Sonic vehicles. As a result, GM is conducting a

safety recall. We apologize for this inconvenience. However, we are concerned about your

safety and continued satisfaction with our products.
IMPORTANT






Your vehicle is involved in safety recall 13296.

Schedule an appointment with your GM dealer.

This service will be performed for you at no charge.
Why is your

vehicle being

recalled?
A front fuel tank strap bracket may separate from the vehicle due to

insufficient welds. If this occurs, the increased load on the

remaining bracket could cause it to separate. The fuel tank would

not be supported by the fuel tank straps and would rest on the

exhaust pipe and/or the plastic fuel tank shield. If this occurs, you

may hear a rattling or scraping noise. If the fuel tank shield and fuel

filler neck do not support the fuel tank, the fuel tank may separate

from the vehicle. If the fuel tank is punctured, and if a source of

ignition is present, a fire could occur.
What will we

do?
Your GM dealer will inspect the front fuel tank strap bracket welds.

If the welds are smaller than specified, your dealer will install rivets

to secure the bracket. This service will be performed for you at no

charge. Because of service scheduling requirements, it is likely

that your dealer will need your vehicle longer than the actual

inspection time of 20 minutes. If the welds require repair, your

vehicle will be needed for an additional 2 hours and 15 minutes.

If your vehicle is within the New Vehicle Limited Warranty, your

dealer may provide you with shuttle service or some other form of

courtesy transportation while your vehicle is at the dealership for

this repair. Please refer to your Owner Manual and your dealer for

details on courtesy transportation.
What should

you do?
You should contact your GM dealer to arrange a service

appointment as soon as possible.
Do you have

questions?
If you have questions or concerns that your dealer is unable to

resolve, please contact the appropriate Customer Assistance

Center at the number listed below.
Page 12
November 2013
Division
Number
Chevrolet

Guam

Puerto Rico – English

Puerto Rico – Español

Virgin Islands
1-800-222-1020

65-6267-1752

1-800-496-9992

1-800-496-9993

1-800-496-9994
Bulletin No.: 13296A

Text Telephones

(TTY)

1-800-833-2438
If after contacting your dealer and the Customer Assistance Center, you are still not satisfied

we have done our best to remedy this condition without charge and within a reasonable time,

you may wish to write the Administrator, National Highway Traffic Safety Administration, 1200

New Jersey Avenue, SE, Washington, DC 20590, or call the toll-free Vehicle Safety Hotline at

1.888.327.4236 (TTY 1.800.424.9153), or go to http://www.safercar.gov. The National

Highway Traffic Safety Administration Campaign ID Number for this recall is 13V454.

Federal regulation requires that any vehicle lessor receiving this recall notice must forward a

copy of this notice to the lessee within ten days.

Jim Moloney

General Director,

Customer and Relationship Services

GM Recall #13296

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