MAHLE MCX-2 User manual

OPERATION MANUAL
MCX-2F
Multiple Coolant Exchanger
Multiple Coolant ExchangerMultiple Coolant Exchanger
Multiple Coolant Exchanger
(With Flush and Flow Indicator)
MAHLE
MAHLE MAHLE
MAHLE Aftermar et Inc., Service Solutions
Aftermar et Inc., Service SolutionsAftermar et Inc., Service Solutions
Aftermar et Inc., Service Solutions
10 Innovation Drive
Yor , PA 17402
800-468-2321
www.servicesolutions.mahle.com
Manual Number 035-82236-00

1
TABLE OF CONTENTS
TABLE OF CONTENTSTABLE OF CONTENTS
TABLE OF CONTENTS
Component Description ............................................................. 2
Safety Precautions ..................................................................... 3
Set-up ........................................................................................ 4
Connection to Power .................................................................. 5
Relieving Radiator Pressure ....................................................... 6
Lowering Coolant Level .............................................................. 7
Connecting to the Coolant System ............................................ 8
Special Hoo ups ........................................................................ 9
Engine Flush ...............................................................................10
Coolant Replacement .................................................................11
Test Coolant System for Lea s ..................................................12
Completing the Job ....................................................................13
Changing Coolant Type ..............................................................15
Emptying the Waste Tan ..........................................................17
Replacement Parts .....................................................................18
Waste Pump Impeller Replacement ...........................................19
Flow & Wiring Diagram ...............................................................20

2
COMPONENT DESCRIPTION
COMPONENT DESCRIPTIONCOMPONENT DESCRIPTION
COMPONENT DESCRIPTION
Unpac all components and verify quantities per this illustration.
Contact MAHLE if any items are missing or damaged.
Wand
New Coolant
Tank
Waste Tank
Small Adapter Hose
Large Adapter Hose
Small Hose Clamps
Large Hose Clamps
1-1/4
1-1/2
Large Step Adapters
Small Step Adapters
VALVE OPEN
1-3/4
VALVE CLOSED
1-1/4
1-3/8
(Qty=2)
Filter & Bowl
1-3/8
1-1/2 1-3/4
Impeller & Gasket
EMPTY WAST E T ANK
FILLR ADIATOR & OV ERFLO W
EXCHANGE C OO LA
NT OR
LOWER RAD IAT OR
&O VERFL OW
&O VERFL OW
LOWER RAD IAT OR
EMPTY WAST E T ANK
EXCHANGE C OO LANT
&O VERFL OW
FILLR ADIA TOR
SYSTEM PR ESSUR E
SYSTEM VACUUM
TEST
OFF
OFF
OFF
Black Hose
Green Hose

3
SAFETY PRECAUTIONS
SAFETY PRECAUTIONSSAFETY PRECAUTIONS
SAFETY PRECAUTIONS
WARNING
WARNINGWARNING
WARNING:
::
: FAILURE TO FOLLOW THESE PRECAUTIONS CAN RESULT IN SERIOUS INJURY
FAILURE TO FOLLOW THESE PRECAUTIONS CAN RESULT IN SERIOUS INJURY FAILURE TO FOLLOW THESE PRECAUTIONS CAN RESULT IN SERIOUS INJURY
FAILURE TO FOLLOW THESE PRECAUTIONS CAN RESULT IN SERIOUS INJURY
OR DEATH.
OR DEATH.OR DEATH.
OR DEATH.
∙ Read and understand the Operation Manual completely before operating this unit.
∙ Always wear proper eye and s in protection when operating and maintaining this equipment.
∙ Ta e precautions to eep clothing, hair, hands, hoses, etc. away from all moving parts on the
vehicle.
∙ Automotive cooling systems can be under pressure and extremely hot. Allow the cooling system
to cool down and use extreme caution when removing caps and hoses.
∙ Coolants are poisonous to people and animals and are also corrosive. Clean up any spills
immediately.
CAUTION:
CAUTION:CAUTION:
CAUTION: FAILURE TO FOLLOW THE PRECAUTIONS AS OUTLINED IN THE OPERATION
FAILURE TO FOLLOW THE PRECAUTIONS AS OUTLINED IN THE OPERATION FAILURE TO FOLLOW THE PRECAUTIONS AS OUTLINED IN THE OPERATION
FAILURE TO FOLLOW THE PRECAUTIONS AS OUTLINED IN THE OPERATION
MANUAL CAN RESULT IN DAMAGE TO THE ENGINE, VEHICLE OR EQUIPMENT
MANUAL CAN RESULT IN DAMAGE TO THE ENGINE, VEHICLE OR EQUIPMENT MANUAL CAN RESULT IN DAMAGE TO THE ENGINE, VEHICLE OR EQUIPMENT
MANUAL CAN RESULT IN DAMAGE TO THE ENGINE, VEHICLE OR EQUIPMENT
WHICH WILL NOT BE SUPPORTED OR COVERED UNDER WARRANTY.
WHICH WILL NOT BE SUPPORTED OR COVERED UNDER WARRANTY.WHICH WILL NOT BE SUPPORTED OR COVERED UNDER WARRANTY.
WHICH WILL NOT BE SUPPORTED OR COVERED UNDER WARRANTY.
∙ Do not allow waste coolant tan to overflow. Immediately clean up any coolant spills. Damage to
the vehicle and equipment can result from the corrosiveness of coolant.
∙ Continuous monitoring of the coolant replacement process is required.

4
SET UP
SET UPSET UP
SET UP
Install Filter and Bowl on rear of MCX-2F as shown. These items are
shipped in the carton with the adapters and adapter hoses.
The MCX-2F has two tan s (plus an extra New Coolant Tan ) which
are installed and connected from the rear. Quic connect couplers are mounted on the hoses which
connect these tan s to the MCX-2F. A green hose connects to the small New Coolant Tan and a
blac hose connects to the large Waste Tan . The small diameter blac drain hose must be inserted
into the hole in the cap of the Waste Tan .
1. Slide the New Coolant Tan to the
rear and sit it on the floor.
2. Remove the tan cap and fill the tan
with new coolant and water in the
proportions specified by the coolant
supplier. The tan can be
disconnected and moved to a bul
coolant storage area for filling if
desired. A plug is provided on the
cap to prevent spillage during
transport.
3. Replace the tan cap and position
the tan in the MCX-2F. Ma e sure
the green hose is securely
connected. Slide the tan to the front
so the liquid level can be seen
through the front panel slot.
4. Ma e sure the plugs are removed from the caps on the Waste Tan and the New
Ma e sure the plugs are removed from the caps on the Waste Tan and the New Ma e sure the plugs are removed from the caps on the Waste Tan and the New
Ma e sure the plugs are removed from the caps on the Waste Tan and the New
Coolant Tan . This is required for venting the tan s during operation. The small diameter
Coolant Tan . This is required for venting the tan s during operation. The small diameter Coolant Tan . This is required for venting the tan s during operation. The small diameter
Coolant Tan . This is required for venting the tan s during operation. The small diameter
blac drain hose must be inserted into the hole in the cap of the Waste Tan
blac drain hose must be inserted into the hole in the cap of the Waste Tanblac drain hose must be inserted into the hole in the cap of the Waste Tan
blac drain hose must be inserted into the hole in the cap of the Waste Tan .
..
.
5. Fasten the clips on the tan strap to secure the tan s in the MCX-2F.
New Coolant Tank
Coupler
Quick
Green Hose
OFF
OF
F
OFF
TEST
SYSTEM VACUUM
SYSTEM PR ESSUR E
FILLR ADIA TOR
&O VERFL OW
EXCHANGE C OO LANT
EMPTY WAST E T ANK
LOWER RAD IAT OR
&O VERFL OW
&O VERFL OW
LOWER RAD IAT OR
EXCHANGE C OO LANT OR
FILLR ADIATOR & OV ERFLO W
EMPTY WAST E T ANK
Black Hose
Green Hose
Tank Cap & Plug
(Small)
New Coolant

5
CONNECTION TO POWER
CONNECTION TO POWERCONNECTION TO POWER
CONNECTION TO POWER
LOWERRADIATOR
&OVERFLOW
EMPTYWASTETANK
OFF
OFF
OFF
TEST
SYSTEMVACUUM
SYSTEMPRESSURE
FILLRADIATOR
&OVERFLOW
EXCHANGECOOLANT
&OVERFLOW
LOWERRADIATOR
EXCHANGECOOLANTOR
FILLRADIATOR&OVERFLOW
EMPTYWASTETANK
The MCX-2F control panel is illustrated above. Note that the bottom of all three selector switches
has been pressed which turns all functions off. Ma e sure all
Ma e sure allMa e sure all
Ma e sure all switches are off before connecting
switches are off before connecting switches are off before connecting
switches are off before connecting
the battery cable clips to the battery of the vehicle.
the battery cable clips to the battery of the vehicle.the battery cable clips to the battery of the vehicle.
the battery cable clips to the battery of the vehicle.
WARNING:
WARNING:WARNING:
WARNING: Handle battery connection cable with extreme caution. Batteries generate
Handle battery connection cable with extreme caution. Batteries generate Handle battery connection cable with extreme caution. Batteries generate
Handle battery connection cable with extreme caution. Batteries generate
explosive gases during normal operation. Wor ing in the vicinity of a lead
explosive gases during normal operation. Wor ing in the vicinity of a leadexplosive gases during normal operation. Wor ing in the vicinity of a lead
explosive gases during normal operation. Wor ing in the vicinity of a lead-
--
-
acid or
acid oracid or
acid or other automotive battery is dangerous. Wear eye protection. Never
other automotive battery is dangerous. Wear eye protection. Never other automotive battery is dangerous. Wear eye protection. Never
other automotive battery is dangerous. Wear eye protection. Never
smo e or allow a spar or flame in the vicinity of the battery. Do not
smo e or allow a spar or flame in the vicinity of the battery. Do not smo e or allow a spar or flame in the vicinity of the battery. Do not
smo e or allow a spar or flame in the vicinity of the battery. Do not
connect the blac power clip to the negative post of the battery to avoid a
connect the blac power clip to the negative post of the battery to avoid a connect the blac power clip to the negative post of the battery to avoid a
connect the blac power clip to the negative post of the battery to avoid a
spar .
spar .spar .
spar .
1. Verify that all switches are in the off position.
2. Connect the red power clip to the “+” (positive) post of the vehicle battery. The battery must
be 12 volt.
3. Connect blac power clip to an engine ground (not the negative post of the battery).
..
.

6
RELIEVING RADIATOR PRESSURE
RELIEVING RADIATOR PRESSURERELIEVING RADIATOR PRESSURE
RELIEVING RADIATOR PRESSURE
WARNING:
WARNING:WARNING:
WARNING: Coolant
Coolant Coolant
Coolant in the vehicle cooling system may be extremely hot and under great
in the vehicle cooling system may be extremely hot and under great in the vehicle cooling system may be extremely hot and under great
in the vehicle cooling system may be extremely hot and under great
pressure. Wear safety glasses and use protective clothing and gloves. Use
pressure. Wear safety glasses and use protective clothing and gloves. Use pressure. Wear safety glasses and use protective clothing and gloves. Use
pressure. Wear safety glasses and use protective clothing and gloves. Use
extreme caution when removing radiator cap and hoses.
extreme caution when removing radiator cap and hoses.extreme caution when removing radiator cap and hoses.
extreme caution when removing radiator cap and hoses.
NOTE: The MCX
NOTE: The MCXNOTE: The MCX
NOTE: The MCX-
--
-2 does not need t
2 does not need t2 does not need t
2 does not need to be connected to power for the following.
o be connected to power for the following.o be connected to power for the following.
o be connected to power for the following.
The MCX-2F will relieve the pressure in a hot-car radiator by drawing a vacuum on the overflow port
on the radiator cap.
Shop air (55 to 100 PSI), connected to the rear port of the MCX-2F causes a vacuum to be pulled on
the small diameter clear hose, also connected to the rear. This clear hose is connected to the
overflow port on the radiator cap as shown above.
The system Vacuum Gauge on the MCX-2F control panel indicates the vacuum level which will
increase until the radiator cap opens and relieves the pressure. As the pressure releases a small
amount of coolant will be seen flowing in the clear hose. When the pressure has been relieved, the
radiator cap will again close and the vacuum level will increase and become steady on the gauge.
The radiator cap can now be slowly and carefully removed.
SYSTEM PRESSURE
OFF
EXCHANGE COOLANT
Clear Hose
Green Hose
Black Hose
EMPTY WAST E T ANK
OFF
EMPTY WAST E T ANK
LOWER RAD IAT OR
&O VERFL OW
&O VERFL OW
LOWER RAD IAT OR
OFF
OFF
SYSTEM VACUUM
EXCHANGE C OO LANT OR
FILLR ADIATOR & OV ERFLO W
TEST
FILLR ADIA TOR
&O VERFL OW
SYSTEM PR ESSUR E
EXCHANGE C OO LANT
Radiator
& OVERFLOW
FILL RADIATOR
& OVERFLOW
LOWER RADIATOR
EMPTY WASTE TANK
TEST
Overflow
Radiator
Hose
Water
Pump
SYSTEM VACUUM
EMPTY WASTE TANK
FILL RADIATOR & OVERFLOW
EXCHANGE COOLANT OR
OFF
OFF
& OVERFLOW
LOWER RADIATOR
Heater
Core
Block
Engine

7
LOWERING COOLANT LEVEL
LOWERING COOLANT LEVELLOWERING COOLANT LEVEL
LOWERING COOLANT LEVEL
WARNING:
WARNING:WARNING:
WARNING: Coolant in the vehicle cooling system may be extremely hot and under great
Coolant in the vehicle cooling system may be extremely hot and under great Coolant in the vehicle cooling system may be extremely hot and under great
Coolant in the vehicle cooling system may be extremely hot and under great
pressure. Wear safety glasses and u
pressure. Wear safety glasses and upressure. Wear safety glasses and u
pressure. Wear safety glasses and use protective clothing and gloves. Use
se protective clothing and gloves. Use se protective clothing and gloves. Use
se protective clothing and gloves. Use
extreme caution when removing radiator cap and hoses.
extreme caution when removing radiator cap and hoses.extreme caution when removing radiator cap and hoses.
extreme caution when removing radiator cap and hoses.
1. Turn both valves on front of MCX-2F to EXCHANGE.
2. Slowly and carefully remove the cap from the radiator.
3. Remove cap from overflow container.
4. Attach the wand to the blac hose. Close the valve.
5. Turn control valve to LOWER RADIATOR & OVERFLOW.
6. Press the top of LOWER RADIATOR & OVERFLOW selector switch to turn on pump.
7. Use the Wand to empty the overflow container and lower the level of coolant in the radiator
to a level just below the upper hose connecting the radiator to the engine. Open valve on
wand as required.
8. Press bottom of LOWER RADIATOR & OVERFLOW selector switch to turn off pump.
9. Replace caps on the radiator and overflow container.
EXCHANGE COOLANT
SYSTEM PRESSURE
EMPTY WAST E T ANK
LOWER RAD IAT OR
&O VERFL OW
SYSTEM PR ESSUR E
&O VERFL OW
LOWER RAD IAT OR
SYSTEM VACUUM
OFF
OFF
OFF
EXCHANGE C OO LANT OR
FILLR ADIATOR & OV ERFLO W
EMPTY WAST E T ANK
TEST
FILLR ADIA TOR
&O VERFL OW
EXCHANGE C OO LANT
Green Hose
Radiator
Radiator
Hose
Black Hose
& OVERFLOW
FILL RADIATOR
& OVERFLOW
LOWER RADIATOR
EMPTY WASTE TANK
TEST
Wand
Water
Pump
Overflow
EMPTY WASTE TANK
OFF
Heater
FILL RADIATOR & OVERFLOW
EXCHANGE COOLANT OR
SYSTEM VACUUM
OFF
OFF
LOWER RADIATOR
& OVERFLOW
Block
Core
Engine
VERY IMPORTANT
VERY IMPORTANTVERY IMPORTANT
VERY IMPORTANT
Open valve on wand only while end is in fluid.
Open valve on wand only while end is in fluid.Open valve on wand only while end is in fluid.
Open valve on wand only while end is in fluid.
Do not suc
Do not sucDo not suc
Do not suc air as the pump may lose its prime.
air as the pump may lose its prime.air as the pump may lose its prime.
air as the pump may lose its prime.

8
CONNECTING TO THE COOL
CONNECTING TO THE COOLCONNECTING TO THE COOL
CONNECTING TO THE COOLANT SYSTEM
ANT SYSTEMANT SYSTEM
ANT SYSTEM
The MCX-2F can be connected to the cooling system in either of the configurations shown below.
The choice is dependent on the ease of accessibility to the hose connections.
1. Turn both valves on front of MCX-2F to EXCHANGE.
2. Disconnect the radiator hose from either the engine or the radiator.
3. Select an Adapter Hose with the same inner diameter as the radiator hose and connect at the
point the radiator hose was disconnected using a clamp.
4. Install Step Adapters in the Adapter Hose and the radiator hose using clamps. Ma e sure the
outside diameter of the Step Adapters is the same as the inner diameter of the radiator hose.
5. Connect the Green and Blac hoses from the MCX-2F to the two Step Adapters as shown in
the illustrations. See next page for special
See next page for specialSee next page for special
See next page for special hoo ups.
hoo ups.hoo ups.
hoo ups.
6. Open the valves on the two Step Adapters.
Water
Pump
Connecting at Engine
OFF
OFF
OFF
TEST
SYSTEM VACUUM
SYSTEM PR ESSUR E
FILLR ADIA TOR
&O VERFL OW
EXCHANGE C OO LANT
EMPTY WAST E T ANK
LOWER RAD IAT OR
&O VERFL OW
&O VERFL OW
LOWER RAD IAT OR
EXCHANGE C OO LANT OR
FILLR ADIATOR & OV ERFLO W
EMPTY WAST E T ANK
Black Hose
Green Hose
Radiator
Hose
Step
Adapters
Overflow
Radiator
Connecting at Radiator
Engine
Block
Green Hose
Black Hose
SYSTEM VACUUM
EXCHANGE C OO LANT OR
FILLR ADIATOR & OV ERFLO W
OFF
OFF
TEST
SYSTEM PR ESSUR E
FILLR ADIA TOR
&O VERFL OW
EXCHANGE C OO LANT
EMPTY WAST E T ANK
LOWER RAD IAT OR
&O VERFL OW
EMPTY WAST E T ANK
OFF
&O VERFL OW
LOWER RAD IAT OR
Hose
Engine
Block
Adapter
Heater
Core
Hose
Adapters
Step
Hose
Adapter
Radiator
Water
Pump
Overflow
Radiator
Heater
Core

9
SPECIAL HOOKUPS
SPECIAL HOOKUPSSPECIAL HOOKUPS
SPECIAL HOOKUPS
Special Hoo up 1) It may be necessary to reverse the hoses during the coolant replacement
procedure on the next page for systems with a reverse-connected
thermostat. See note after Step 6 on next page for the symptoms of this
situation.
Special Hoo up 2) Some cooling systems do not have a cap on the radiator. Instead, there is
a single cap on the overflow tan as shown in the illustration below.
The hoses to and from the overflow tan must be pinched using hose
pinching pliers during the coolant replacement procedure on the next page.
Failure to pinch these hoses will cause fluid to be forced out of the vented
cap on the overflow tan during the coolant replacement procedure.
Block
Engine
Adapters
HOSE
PINCH
Hose
Radiator
PINCH
HOSE
Overflow
Pump
Water
Step
Hose
Adapter
Heater
Core