502799 screws and # 500855 washers.

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•

Connect the PLASMA 3 and the PLASMA 4 connectors (previously routed to the underside of the
parcel rack) to the two modules. Leave +/- 6 inches of wire behind the module to ease future
removal / installation during maintenance.

•

Secure the supports (and modules) to the extrusion using the supplied # 500443 screws.

Writer: mg

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7. Route the # 0610505 harness from the HVAC unit to the front defrost unit area.
•

Remove the driver window pillar cover. Also remove the dash cover and the defrost unit cover.

•

Connect the C581 connector of the # 0610536 harness (previously routed under the HVAC unit
with PLASMA 3 & 4 connectors) to the C581 connector of the long # 0610505 extension harness.

•

Using a fish tape or a long flexible rod, pass the # 0610505 harness inside the parcel rack frame
up to the driver’s pillar area.

•

Follow the pillar down (use cable ties) and using a flex rod, fish the harness inside the front
electrical junction box.

•

Secure the harness inside the front junction box (in the upper area from rear to the front)

•

Still using the flex rod, route back the harness C580 connector inside the vehicle up to the
dashboard area.

•

Pass the harness over the dash cluster (secure with supplied cable ties) and make the C580 connector exit near the front defrost unit cover.

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8. Install two # 0610449 plasma cluster modules in the front defrost unit.
•

Remove the defrost unit cover screws and slide the cover out.

•

From inside the cover, mark the required new holes center point with a sharpie and drill the holes
using the appropriate step drill bit (see image below for hole size and positioning). Use # 370377
bracket as a template to mark and drill the remaining holes as shown.

•

Using the supplied # 504335 rivets, fasten the two # 370377 supports to the inside of the cover.

•

Insert the # 0610503 harness through the larger 21.5mm hole making sure that the C580
connector is positioned outside the cover and that the PLASMA 1 and PLASMA 2 connectors are
inside.

•

Insert the harness grommet in the 21.5mm hole.

•

Clip the # 564108 self-mounting support on the outside of the cover (5mm & 6.5 mm holes) and
secure the C580 connector to it (connector pointing upward).

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•

Connect 2 # 0610449 plasma cluster modules to the PLASMA 1 and PLASMA 2 connectors.

•

Install the plasma cluster modules to the brackets using supplied # 502799 screws and # 500855
washers.

•

Install the supplied # 509815 cable tie mounting clips and secure the harness (use supplied cable
ties).

•

Reinstall the defrost unit cover.

•

Connect the # 0610503 harness C580 connector to the C580 connector previously routed under
the dashboard cover (# 0610505 harness).

•

Secure the wiring on top of the defrost unit & reinstall all covers previously removed in the driver’s
area.

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9. Install the # 0610534 harness inside the vehicle under the curb side HVAC unit
•

Drill a 1-inch hole in the last baggage compartment ceiling at the opposite corner of the DC/DC
converter (front right of the compartment). The hole should be drilled about 2 inches next to the
AC drain hoses as shown in the pictures below.

•

Secure the C583 connector and wires of the # 0610535 wiring harness (harness connected to the
DC/DC converter) along the walls of the baggage compartment next to the 1-inch hole as shown.

•

Inside the vehicle, remove the window pillar covers adjacent to the HVAC unit in the parcel rack.

•

Using a fish tape or a flexible rod, pass the PLASMA 9 & the PLASMA 10 behind the interior trim
up to the base of the window pillar.

•

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

•

Insert the PLASMA 9 & the PLASMA 10 connectors inside the cavity under the parcel rack floor
and extend the connectors so they lay under the HVAC unit.

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10. Install 2 plasma cluster modules # 0610449 in the area below the right 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 #
502799 screws and # 500855 washers.

•

Connect the PLASMA 9 and the PLASMA 10 connectors (previously routed to the underside of
the parcel rack) to the two modules. Leave +/- 6 inches of wire behind the module to ease future
removal / installation during maintenance.

•

Secure the supports (and modules) to the extrusion using the supplied # 500443 screws.

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11. Drill and cut the necessary opening and holes through the condenser compartment duct.
•

Using the supplied # 454776 template, cut an opening in the condenser duct. Use the outside
of the template to cut through the insulation material and the inside edge to cut through the
plastic duct as shown.

•

Also use the template to mark and drill the 8 mounting screw holes.

•

Inside the duct, trial fit the # 454853 & # 454854 supports and mark the mounting screws position.
−

Two screws (on both sides) are already passing through the duct plastic shell. The
supports center holes must fit over the lower screws to position them in the duct.

−

Adjust the top of the supports flush with the top duct opening as shown.

−

Use some masking tape to hold the supports in place and mark the supports mounting screws position with a paint marker.

•

Drill the screw mounting holes on both sides of the duct (an angle drill will be necessary).

•

On the exterior side of the duct, drill a 7/8 inch opening +/- 3 inches before the previously
drilled mounting hole as shown.

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12. Route the PLASMA 7 & PLASMA 8 connectors (# 0610535 harness) from the evaporator
compartment up to the inside of the condenser duct.
•

Locate the PLASMA 7 & PLASMA 8 connectors in the evaporator compartment (part of the #
0610535 harness).

•

Pass both connectors in the condenser compartment through the electrical PVC conduit as
shown below (use a long rod to fish the connectors out of the grommet).

•

Insert both connectors in the previously drilled 7/8 inch hole on the side of the condenser duct.

•

Insert the harness grommet in the hole to secure the harness in the duct.

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13. Install two plasma cluster modules & supports in the condenser duct.
•

Connect a plasma cluster module to the PLASMA 7 & PLASMA 8 connectors inside the duct.

•

Mount the connected modules to their supports using the supplied # 502799 screws & # 500855
washers. For this particular location, the left side module will be pointing up.

•

Secure the supports to the sides of the duct using the supplied # 500356 screws and # 5001744
toothed washers.

•

Install the 8 # 5002071 spring nuts over the duct cover screw holes.

•

Apply a strip of # 506268 3/8” foam tape around the # 454774 condenser closing cover.

•

Seal the duct opening with the cover using supplied # 5001155 screws.

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14. Connect the plasma cluster system to the vehicle power source.
•

In the evaporator compartment, locate the R12 relay and the ground stud on the firewall.

•

Connect the power terminal of the plasma cluster system to the middle terminal of the R12 relay.

•

Connect the ground terminal of the system to the ground stud.

•

Make sure both 5 amp fuses in the system are good before powering the vehicle.

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15. Apply the Prevost EnviroCare decal on the vehicle body.
•

Clean the area just over the X345 crest near the entrance door. Use isopropyl alcohol or anti silicone (some other decals may also be present in the area).

•

In Canada, carefully apply the bilingual decal # 0610528 just above any already installed factory
decals (leave around 10mm gap between decals).

•

In the United States, carefully apply the English decal # 0611019 just above any already installed
factory decals .Leave around 10mm gap (3/8in) between decals.

IMPORTANT: Make sure the surface is clean and dry. Do not apply in cold temperature, heat the area as
necessary to ensure proper adhesion.

16. Finish the installation and proceed to the system tests.
•

Seal the two 1 inch openings in the baggage compartment using the supplied # 680453 butyl
paste.

•

Secure all loose wires & harnesses using supplied cable ties.

•

Reinstall all trim parts & covers in the vehicle.

•

Proceed with the test procedure at the end of this document to ensure proper function.

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PLASMA CLUSTER INSTALLATION - IN VEHICLE TESTS

TESTER CALIBRATION

1. To operate the meter, flip the POLARITY switch to its center position, halfway between "+"
and "-", and the MEASURE switch to the STANDBY position.
2. Turn the RANGE knob to the 199.9 position.
3. Wait until the display becomes stable to within +/-2 counts. This will take about 10 seconds
after the meter is turned on.
4. Adjust the OFFSET knob so that the display reads zero +/- 2 counts (+/- 0.02). After this
step, the OFFSET might not need to be readjusted again, ever. However, it should be
checked at the beginning of each measurement session or if the temperature changes
significantly.

NOTE
If you change the knob to another range like "19.99", you will not need to readjust the
OFFSET.

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TEST POINTS & EXPECTED RESULTS:
AT LOWER WINDOW EXITS

1. At the lower window height, the removable
air shroud must be removed for accurate
measurements.
2. Ground the tester to the Audio/Video
mounting plate in the first parcel rack or the
AC unit bodies in the parcel racks.
3. Flip the POLARITY switch to whichever
polarity ("+" or "-") you want to measure (the
MEASURE switch set at the STANDBY
position). Wait for the display to become
stable.
4. Wait at least 10 seconds after flipping the
POLARITY switch then flip to the
MEASURE position (switch upward). This
will turn on the fan.
5. Place the tester opening in the middle of the
airflow exiting from the grille.
•
•
•

•

Take a reading in the center of the
steering wheel.
Take a second measurement in the
middle of the entrance handrail.
On the curb side of the vehicle, take a
reading in the middle of the 2nd and
the 5th windows.
On the curb side of the vehicle, take a
reading in the middle of the 3rd and
the 5th windows.

6. At the 199.9 scale, the readings should top
off and read –I (INFINITE).
On vehicles equipped with a Wheel Chair
Lift, a slightly lower reading of 150+ is
acceptable at the 5th window (behind the
WCL).

Writer: mg

WARNING !
Make sure that the tester airflow (rear fan
area) is not blocked by either your hand,
body, vehicle component (Ex: steering
wheel) or other solid object.

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AT PARCEL RACKS OVERHEAD AIR REGISTERS

1. At the overhead registers, the removable air
shroud must be removed for accurate
measurements.
2. Ground the tester to the AC unit body in the
parcel racks.

3. Flip the POLARITY switch to whichever
polarity ("+" or "-") you want to measure (the
MEASURE switch set at the STANDBY
position). Wait for the display to become
stable.

4. Wait at least 10 seconds after flipping the
POLARITY switch then flip to the
MEASURE position (switch upward). This
will turn on the fan.
WARNING !
Make sure that the tester airflow (rear fan
area) is not blocked by either your hand,
body, vehicle component (Ex: steering
wheel) or other solid object.

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5. Place the tester opening in the airflow
stream exiting from the register grille.

•

Take a reading at the register right in
front of the AC unit.

•

Take a reading at the register located
just after the AC unit.

•

Do both sides of the vehicle (4
readings total).

6. At the 199.9 scale, the reading should top
off and read –I (INFINITE).

Writer: mg