Electrolysis Corrosion
Electrolysis is a highly desructive reaction casued by the passage of electrical current through coolant which destroys its corrosion prevention properties. It is a menace that attacks radiators and heaters and can destroy an entire engine within 12,000 miles. Electrolysis occurs when electrical current flows through engine coolant in search of ground. It is most commonly caused when an electrical component or accessory somewhere in the vehicle loses ground usually from a loose or broken wire. When electrical devices lose their normal electrical path to the chassis or battery ground the current seeks out any failure route. In most cases of radiator or heater failure loose or missing grounds can be tracedto electrical cooling fans or relays. Another cause is bad ground wire from the engine to the chassis.

Fitting New Core - No Accident Damage

1. Before removing the radiator, check the existing coolant for an electrical charge. This is done by connecting the voltmeter between the coolant and battery ground. The meter should have a range of at least 12 volts (assuming the vehicle has a 12 volt electrical system) and a sensitivity of at least one tenth of a volt. By connecting one test lead to a battery ground and placing the other in the coolant (DO NOT TOUCH THE METAL CORE OR FILLER NECK) ANY voltage reading indicates the presence of current through the coolant - ELECTROLYSIS.
2. If no current is found, flush out the existing coolant or inhibitor with a quality alkaline cooling system flush. Drain and rinse the cooling system including the overflow bottle with water and fit the new radiator.
3. Select coolant or additive for the vehicle as per the manufacturers' recommendations and refill the cooling system. Bring engine upto temperature and let it cool. Re-check the coolant level and top up if necessary.
4. IMPORTANT - Again check the coolant for any current as per procedure 1 and ensure the reading is below 0.05 volts. If a positive reading is found, the source of the current must be located as this current could destroy the radiator and the engine.

Fitting New Core - Accident Damage

1. No initial reading can be taken if the original radiator is damaged.
2. Fit the new radiator. Flush the cooling system and the overflow bottle to remove any old coolant inhibitor. Only use a quality flushing compound.
3. Select coolant or additive for the vehicle as per manufacturers recommendations and refill the cooling system. Bring engine upto temperature and let it cool. Re-check the coolant level and top up if necessary.
4. IMPORTANT - Check the coolant for any current as per procedure 1 NO ACCIDENT DAMAGE and ensure the reading is below 0.05 volts. If a positive reading is found the source of the current must be located as this current could destroy the radiator and the engine.