Though modified ignition switches were fitted at the factory, General Motors is now recalling some 2008-2011 models because it has no way of knowing if any car has since been repaired using one of the older types of switch.

The automaker will now replace the ignition switch in all model years of its Chevrolet Cobalt, HHR, Pontiac G5, Solstice and Saturn Ion and Sky in the US.

GM records indicate the service parts may have been used for ignition repairs in:

  • 2008-2010 Chevrolet Cobalt
  • 2008-2011 Chevrolet HHR
  • 2008-2010 Pontiac Solstice
  • 2008-2010 Pontiac G5 and
  • 2008-2010 Saturn Sky

The parts are at the centre of the company’s recently announced ignition switch recall which originally extended to the 2007 model year.

But about 95,000 faulty switches were also sold to dealers and aftermarket wholesalers. Of those, about 90,000 were used to repair older vehicles before they were recalled in February.

Because it is not feasible to track down all the parts, the company is taking the extraordinary step of recalling 824,000 more vehicles in the US to ensure that every car has a current ignition switch.

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GM said it was unaware of any reports of fatalities with this group of vehicles where a frontal impact occurred, the front air bags did not deploy and the ignition was in the ‘accessory’ or ‘off’ position.

As with the earlier recalls, if the torque performance is not to GM specification, the ignition switch may unintentionally move from the ‘run’ position to the ‘accessory’ or ‘off’ positions, leading to a loss of power. The risk may be increased if the key ring is carrying added weight or if the vehicle goes off road or experiences some jarring event. The timing of the key movement out of the ‘run’ position relative to when the sensing algorithm of a crash may result in the air bags not deploying, increasing the potential for occupant injury in certain kinds of crashes.

Until the recall has been performed, GM is urging customers to remove all items, including the key fob, from their key rings, leaving only the vehicle key.

“We are taking no chances with safety,” said GM CEO Mary Barra. “Trying to locate several thousand switches in a population of 2.2m vehicles and distributed to thousands of retailers isn’t practical. Out of an abundance of caution, we are recalling the rest of the model years.”

Owners who may have had a suspect part installed will receive a letter the week of 21 April. GM dealers will replace their ignition switch free of charge as parts become available. Customers who paid to have their ignition switches replaced will be eligible for reimbursement.

Dealers, distributors and other parts customers will be told about the recall starting today, 31 March.

Separately, the automaker confirmed an additional fatality associated with the ignition switch condition involved in the current recall.

The 2013 event involved a 2007 model year Chevrolet Cobalt in Quebec, Canada.

“GM is working cooperatively with Transport Canada and has notified US government authorities.  The total number of fatalities associated with the ignition switch recall now stands at 13,” the automaker said in an emailed statement.

“As previously announced, GM has commenced an intensive review led by well-respected former US Attorney Anton Valukas to get an unvarnished understanding of the circumstances leading up to the recall.  We are deeply sorry for the loss suffered by our customers and we will work to regain their trust.”