Why haven’t I heard of Electrolysis?
Before the days of front-wheel drive and transverse-mounted engines, cooling system electrolysis was a rare occurrence. But today, with most cars and many light-duty trucks featuring electric cooling fans in conjunction with ungrounded plastic-tank radiators, cooling system electrolysis is becoming a frequent problem. Whether factory installed or aftermarket add-ons, electric motors, sensors, and task-specific microprocessors are packed into today’s cars, vans, pickups, and SUVs. While the gadgets are interesting, if not always practical, they have greatly complicated the task of diagnosing and repairing today’s vehicles. In fact, the proliferation of electronic gadgetry, under the hood as well as under the dash, has triggered a whole new set of vehicle problems and diagnostic challenges. Besides attacking radiators and heaters, electrolysis can be a fast-acting menace that reportedly has destroyed an entire engine in a mere 20,000 miles due to reactions between the coolant and cooling system metals. A small amount of measurable voltage can be detected in most engine cooling systems. The detected voltage should never exceed a tenth (.10) of a volt in vehicles equipped with aluminum engine blocks and/or cylinder heads. Cast iron engines and cooling system components can tolerate higher stray voltages, perhaps as much as three-tenths (.30) of a volt. But that doesn’t mean that three-tenths are acceptable, it’s not.
What causes Electrolysis?
In cases of electrolysis, a defective or missing ground on an electrical device causes the electricity to seek the path of least resistance whenever the device is turned on. Sometimes the path of least resistance is coolant in the radiator or heater hose, or the radiator or heater itself. As the electrical current drawn by the poorly grounded accessory increases, so does the destructiveness of electrolysis. It has been reported that a poorly grounded engine and starter motor can zap enough current through the cooling system to damage a heater or radiator in a matter of weeks, depending on how often the vehicle is started. A partially grounded electric cooling fan, on the other hand, may only shoot a small percentage of its supply current through a cooling system, and the cumulative damage may take months or even years to reveal itself. It has also been proven that coolant flowing through dissimilar metals in the cooling system increases the incidence of “production” of electrical current as it goes through the system. Components which have aluminum and stainless steel which have coolant going through them are such examples. Evidence of electrolysis includes unexplained and/or recurring pinhole leaks in a radiator or heater. Pinholes may form anywhere along the tubes or tank walls. Damage is often concentrated at tube-to-header joints. Some industry professionals have even reported problems in the tube walls near the center of the core, where the electric cooling fan mounts come in contact with the radiator core.
How fast can Electrolysis work?
Industry sources tell us of one case where electrolysis completely destroyed a brand new aluminum radiator in less than 30 days. Aluminum affected by electrolysis can corrode rapidly in the form of flakes. These flakes will suspend in the cooling system and eventually build up causing system failure. Cast iron engine components can corrode, causing rust or scale to form, contaminating the coolant and allowing the system to slowly destroy itself. Premature part failures, overheating, and deposit formations are some common symptoms of electrolysis or are caused by electrolysis.
