Instruction Sheet

IS-21901

X3 SERIES ENVIROCARE - IONS AIR SANITIZER
Effective vehicles: 2009+ (and up)

First Release

09-09-2021

MATERIAL
Kit #0611017 includes the following parts:
Part No.

Description

Qty

0610449

PLASMACLUSTER

10

0610510

SUPPORT CONVERTER DC-DC (1)

1

0610511

SUPPORT CONVERTER DC-DC ASSY. (2)

1

314937

PLASMA CLUSTER BRACKET, PARCEL RACK

4

370377

PLASMA CLUSTER BRACKET, DEFROST UNIT

2

5001996

SCR MA PAN PH N500 M4-0.7X12

6

0610505

WIRING, PLASMA CLUSTER PARCEL RACK

1

5002071

NUT SPR U #8 .110-.187

14

0610503

WIRING, PLASMA CLUSTER DRIVER

1

500443

SCR TP PAN PH N500 #8X1/2

10

0610536

WIRING, PLASMA CLUSTER EVAPORATOR X3

1

500539

NUT HEX NYRT NX500 M4-0.7

2

0610535

WIRING, PLASMA CLUSTER DC/DC X3

1

500591

WSH FL Z050 4.3X9X.8 (M4,#8)

1

0610534

WIRING, PLASMA CLUSTER CONDENSER X3

1

504637

CABLE TIE, NYLON BLK (STD)

40

Writer: mg

IS-21901
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454774

CLOSING, CONDENSER DUCT

1

502799

SCR CAP HEX N500 M4-0.7X16 G8.8

24

WSH FL N500 .188X.438X.049 (M4,#10)

24

504273

CABLE TIE, NYLON BLK (SMALL)

20

506268

TAPE AD1 URE OP GY 3/8"X1/2"X25'

454854

SUPPORT ASS.

1

504335

RVT POP DOME AL CLE 3/16 (0.063_0.125)

6

509815

FIR TREE MOUNTING (FT7 TYPE)

7

0611019

DECAL (EN)

1

562679

4 WAY ADH. SQUARE BACKED MOUNTS

10

0610528

DECAL (EN/FR)

1

564108

SELF-MOUNTING STUD

1

564288

DC/DC (24/12V) CONVERTER

1

454770

SUPPORT PLASMA CLUSTER,EVAP.DUCT
ASSY

1

454853

SUPPORT ASS.

1

0610547

DC/DC CONVERTER DECAL

1

952624

CLAMP P STL ZP RUB 7.9 ID

1

500356

WSH LO SERR N500 6.1X16X.9 (M6)

4

5001744

SCR CAP HEX N500 M6-1.0X16 G8.8

4

500855

Writer: mg

0.25

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504555

GROMMET .5MENBX.8125X.125X.3438X1.0625

680453

BUTYL CLEAR 1/32 X 1/2

504534

GROMMET .875X1.250X.1875X.5625X1.625

506071

TAPE AD1 PE CC BK 1/8"X1/2"X60'

5001155

SCR TP PAN PH N050 #8X3/4

1
0.2
2
0.1
22

504013

CABLE TIE MOUNT, BLACK 1/4"

2

454775

CUTTING TEMPLATE EVAP.

1

454776

CUTTING TEMPLATE COND.

1

IS-21901

INSTRUCTION SHEET (EN)

1

FI-21901

INSTRUCTION SHEET (FR)

1

Other parts that may be required:
Part No.

Description

7771197

AIR ION COUNTER (TESTER)

Qty
1

NOTE
Material can be obtained through regular channels.

PROCEDURE

DANGER
Park vehicle safely, apply parking brake, stop engine. Prior to working on the vehicle, set the ignition switch
to the OFF position and trip the main circuit breakers equipped with a trip button. On Commuter type vehicles, set the battery master switch (master cut-out) to the OFF position.
Lock out & Tag out (LOTO) must be performed during set-up, maintenance or repair activities. Refer to your
local procedure for detailed information regarding the control of hazardous energy.

Writer: mg

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1. Install the # 564288 DC/DC converter in the vehicle last street side baggage compartment.
•

Using 2 of the supplied # 5001155 screws, secure the # 0610510 part of the support to the vehicle
ceiling (see picture for actual location). There should be +/-10cm gap between the support and the
vehicle structure.

•

Apply the # 0610547 decal to the front face of the DC/DC converter (inputs & polarity).

•

Pre-install the DC/DC converter # 564288 to the other half of the support (# 0610511). Use 4 #
502799 screws and 4 # 500855 washers.

•

Secure that assembly to the previously installed support half in the vehicle, use 2 loosely screwed
# 5001996 screws.

•

Secure the top of the assembly to the ceiling using 2 other # 5001155 screws.

•

Tighten the support # 5001996 screws to secure both parts of the support together.

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2. Pass the # 0610535 harness R12 connector (ring terminal with black fuse holder), the ground
terminal, the C582, the PLASMA 7 & PLASMA 8 connectors in the evaporator compartment
through the compartment harness opening (grommet).
Pass a fish tape or a flexible rod through the baggage/evaporator wall grommet (some cable ties
may need to be removed around the rubber boot).

•

NOTE
−

Do not connect the R12 connector (POWER+) and the GRND terminal yet.

−

Keep wires loose, secure only after final connection.

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3. Connect the DC/DC converter to the # 061502 wiring harness.
•

Connect the DC/DC converter outputs and input wires as shown in the picture below. Wires are
numbered, make sure the order is correct.

NOTE: Make sure that the converter outputs & inputs are identified using the supplied # 0610547 decal.
•

Connect the DC/DC converter ground wire to the converter body.

•

Secure the clear fuse holder to the side of the DC/DC converter support using a # 5001996 screw
as shown (make sure that there is a good 5-amp fuse in the fuse holder).

•

Secure the harness to the ceiling using the supplied # 504013 mounts # 5001155 screws and
cable ties.

•

Secure the fuse holder harness to the support using the supplied # 952624 clamp, # 500539 nylon
lock nut and # 500591 washer. Use the free length of the previously installed converter to support
screw as shown.

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4. Route the # 0610536 harness inside the vehicle on the evaporator side.
•

Position the supplied # 454775 template on the top part of the duct (template must contact the
upper metal edge).

•

Using a light-colored paint marker, draw the position of the opening.

•

Also mark the position of the 6 support plate screws.

•

Cut the opening in the duct.

•

Drill all screw marks using a 1/4 inch drill bit.

•

Install 6 of the supplied # 5002071 spring nuts over the screws openings.

•

Connect the # 0610536 harness C582 connector to the C582 connector (# 0610535 harness
previously routed in the grommet) in the evaporator compartment.

•

Drill a one-inch hole in the evaporator compartment ceiling next to the AC drain tube.

•

Pass the PLASMA 5 & PLASMA 6 connectors (# 0610536 harness) through the hole and route
them to the inside of the evaporator duct.

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•

Inside the vehicle, remove the window pillar cover (pillar just over the DC/DC converter)

•

Using a fish tape or a flexible rod, pass the PLASMA3, the PLASMA 4 and the C581 connector
behind the interior trim up to the base of the window pillar.

•

Route the connectors along the window pillar (secure to the AC drain hose).

•

Insert the PLASMA 3 & the PLASMA 4 connectors inside the cavity under the parcel rack floor
and extend the connectors so they lay under the AC unit.

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5. Install two plasma cluster modules in the HVAC duct on the evaporator side.
•

Put a strip of # 506071 (thin 1/8”) foam tape all around the # 454770 evaporator support
assembly.

•

Connect two # 0610449 plasma cluster modules to the PLASMA 5 & PLASMA 6 connectors in
the evaporator duct opening.

•

Secure the connected plasma cluster modules to the support assembly using supplied # 502799
screws & # 500855 washers.

•

Secure the support assembly to the evaporator duct using 6 # 5001155 screws.

6. Install 2 plasma cluster modules # 0610449 in the area below the left parcel rack HVAC unit.
•

With a sharpie, mark the location of the # 314937 supports (2X) on the inner parcel rack rail. Both
supports must contact the extrusion edges, one on both sides (the support back shape must fit
the ribbed extrusion profile horizontally as shown).

•

Drill the 4 mounting points for a # 8 screw (1/8 or 9/64th inch drill bit).

•

Install 2 of the supplied # 0610449 plasma cluster modules on the supports using supplied #