Jeep LJ Cummins R2.8 Build - Electrical Documentation¶
Project Overview¶
This documentation covers the complete electrical system design for a 2006 Jeep LJ (Wrangler Unlimited) with a Cummins R2.8 Turbo Diesel engine swap. The factory wiring and TIPM are replaced with a modular architecture: dual isolated batteries, programmable power management (PMU24), a safety controller (SafetyHub), and split control surfaces for street lighting (Command Touch CT4) and offroad lighting (SwitchPros SP-1200). Brakes are converted to electro-hydraulic (Bosch iBooster + Wilwood master cylinder), and ignition is keyless via PBS-I.
System Architecture¶
The electrical system is organized into zones for logical distribution and maintenance:
Power Systems¶
- Power Generation - Batteries, alternator, BCDC, solar, grounding
- START battery Distribution - Driver rear wheel well primary power distribution
- AUX battery Distribution - Passenger rear wheel well accessory power distribution
- Power Management Unit - PMU24 programmable power management
- BODY PDU - Body relay/fuse panel
- SafetyHub - Safety control system
Critical Systems¶
- Starter System - Engine starting system
- Brake Booster - Bosch iBooster Gen 2 + Wilwood master cylinder
- HVAC System - Heating, ventilation, and air conditioning
- Wiper System - Windshield wipers
- Horn System - Vehicle horn
- Radiator Fan - Engine cooling fan
- Grid Heater - Diesel grid heater
- Fuel System - Fuel pump and delivery
- Gauge Cluster - Dakota Digital HDX cluster + BIMs
- Runaway Protection - Diesel runaway shutoff
Lighting Systems¶
- Lighting Overview - Complete lighting system overview
- Headlights - Main headlights
- Turn Signals - Turn signal system
- Tail, Brake & Reverse - Rear lighting
- DRL & Parking Lights - Daytime running and parking lights
- Offroad & Aux Lighting - Auxiliary and offroad lighting
Control Interfaces¶
- Overview - Control systems overview
- SwitchPros SP-1200 - SwitchPros lighting controller
- Command Touch CT4 - Command Touch control panel
- Dashboard Switches - Physical dashboard controls
- Keyless Ignition - PBS-I keyless start
Stereo Systems¶
- Audio Systems - Fusion head unit, JL Audio MV800/8i 8-channel amp, JL Audio speakers and subwoofers
Communications¶
- Communication Systems - GMRS radio, intercom, dash camera
Auxiliary Systems¶
- Winch - Warn Zeon 10-S winch (10,000 lb)
- Air Compressor - ARB Twin Compressor and tank
- Air Lockers - ARB RD116 front/rear lockers
- Rear Air Chuck - External air access
Drivetrain¶
- Drivetrain Overview - Transmission, transfer case, axles, suspension, steering
Installation¶
- Installation Overview - Build sequence, checklists, purchase tracker
- Wire Routing & Layout - Physical wire routing, grommets, grounds
Key Features¶
Dual Battery System¶
- START battery: Driver rear wheel well - powers critical engine systems via PMU and SafetyHub
- AUX battery: Passenger rear wheel well - powers accessories via inline CBs + Firewall CONSTANT bus (cabin distribution cluster)
- Battery Isolation: RedArc BCDC Alpha 50 DC-DC charger with automatic jump-start assist
See Power Generation for complete battery and charging system details.
Modular Power Distribution¶
The factory TIPM is replaced with discrete, serviceable modules:
- PMU24: Programmable 24-channel power management unit
- BODY PDU: Body relay/fuse panel for cabin accessories
- SafetyHub: 12-channel advanced safety controller
- Ron Francis WS-51C: Wiper control module
Brake & Ignition¶
- Bosch iBooster Gen 2 + Wilwood MC: Electro-hydraulic brake booster (Honda Accord Hybrid Gen 2 iBooster, Wilwood Tandem Compact master cylinder, Back Bay Customs adapter)
- PBS-I Keyless Ignition: Pushbutton start, self-contained RFID immobilizer (no PMU dependency)
Major Systems¶
- Lighting Control: SwitchPros SP-1200 for offroad and auxiliary lighting
- Command Touch CT4: Street-legal lighting and turn signal control
- Audio System: JL Audio MV800/8i 8-channel amp w/ DSP, JL Audio marine speakers and 2× 8" subs with RGB LED
- Communication: Rugged Radio G1 GMRS, STX 4-place intercom, WolfBox dash camera
- Recovery & Air: Warn 10,000 lb winch, ARB air lockers, ARB Twin Air Compressor
TBD Tracker — Open items and unresolved specs.
Print / Download¶
Print page combines all docs into a single binder-ready page (US Letter, duplex, binding margins).