Electrolysis is a hidden but serious problem in cooling systems where electrical current passes through the coolant, causing metal components (especially aluminium radiators) to corrode from the inside. This leads to pinhole leaks, rapid deterioration, and cooling failure.

⚠️ What Causes Electrolysis?

•   Poor grounding (earthing) in the vehicle
•   Faulty or damaged electrical wiring
•   Mixing different coolant types
•   Old or contaminated coolant losing its protection
•   Use of tap water instead of distilled water
•   Dissimilar metals reacting inside the system

👉 Even a small voltage can cause damage over time

🔍 Signs of Electrolysis

•   Unexplained coolant loss
•   Repeated radiator or heater core failures
•   Pinhole leaks in aluminium components
•   Discoloured or rusty coolant
•   Electrical tingling when touching coolant (in severe cases)

🛑 How to Avoid It

•   Use correct, high-quality coolant
•   Always mix with distilled water
•   Ensure proper engine and chassis grounding
•   Regularly flush and replace coolant
•   Avoid mixing incompatible coolant types
•   Check electrical system for faults

🔧 How to Fix It

•   Test for stray voltage (using a multimeter in coolant)
•   Repair faulty grounds and wiring
•   Flush the entire cooling system thoroughly
•   Replace damaged components (radiator, heater core, etc.)
•   Refill with correct coolant mixture
•   Re-test system to ensure issue is resolved

🔥 Why It’s Serious

•   Can destroy a radiator in weeks or months
•   Causes hidden internal damage
•   Leads to repeated failures if not fixed properly

⭐ our Tip

If you’ve replaced a radiator more than once, electrolysis could be the cause, testing and proper grounding are essential to prevent repeat damage.