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Section 2: Engine Systems - Installation Checklist

Organized by installation order for efficient build workflow.

Procurement

iBooster

  • Source 03-06 TJ/LJ automatic brake pedal assembly (donor)
  • Source new stop-lamp switch + clip if donor pedal lacks them (Mopar 56045043AB)
  • ~~Source Bosch iBooster Gen 2 unit~~ — ✅ purchased 2026-05-30 (Honda Accord Hybrid donor, listing #397546491129; OEM 46680-T3Z-A00 + 01469-TWA-A58 confirmed on listing; MC pull included will be discarded)
  • Order Back Bay Customs Wilwood MC adapter (260-15542 fitment confirmed by vendor 2026-05-30 — Honda iBooster only)
  • Order Wilwood 260-15542 Tandem Compact master cylinder (1.00" bore — sized to TJ Rubicon front calipers)
  • Order Wilwood 260-16392 remote reservoirs (×2) + 250-16393 dual bracket
  • Order Wilwood 220-12993 -3 AN flexlines (×2) - confirm length after firewall mockup
  • Select iBooster wiring harness: Tulay's Gen 2 vs EVcreate Gen 2 kit
  • Redesign backing-plate DXF to 60×80mm hole pattern (was 72×72mm), then order SendCutSend cabin-side backing plate (3/16" steel, 4× M8 clearance holes at 60×80mm, 80mm vertical + 62mm center pass-through) — booster mounts directly via integral studs, no separate bracket needed

Wipers

  • Order Ron Francis WS-51C wiper controller module

Runaway Protection

  • Order Mishimoto MMOCC-CBT catch can + MMOCC-UB bracket
  • Order AMOT 4261M02A027-AA air shutoff valve (2.8", manual/pneumatic, NPT)
  • Order Midwest Control 30-144-TTL-BH-3 push-pull cable + T-handle
  • Measure R2.8 turbo inlet OD and order matching NPT-to-hose adapters
  • Source 2 ft of 5/8" oil-resistant hose + worm clamps for catch can plumbing

Phase 1: Starter System

  • Confirm starter motor (DB Electrical 410-52442) mounted to engine block
  • Confirm 2/0 AWG cable from START battery+ to starter battery post
  • Confirm Cole Hersee 24213 solenoid mounted on firewall (engine bay side)
  • Confirm 10 AWG from starter battery post to Cole Hersee input
  • Confirm 10 AWG from Cole Hersee output to starter switch post
  • Confirm PBS-I module mounted under-dash (cabin), powered from Critical Cabin PDU
  • Confirm PBS-I PURPLE START output wired to WAIT-gate relay COM terminal (cabin)
  • Confirm WAIT-gate relay coil wired to ECM WAIT signal tap (shared with HDX WAIT/EX input)
  • Confirm WAIT-gate relay NC contact routed through firewall Pin 15 → Cole Hersee 24213 coil+ in engine bay
  • Confirm Cole Hersee coil- grounded to engine bay ground bus
  • Confirm PBS-I PINK IGN routed through cabin ignition signal bus bar → firewall Pin 12 → ECM 12V supply + PMU Pin 7
  • Confirm Start Button (included in PBS-I kit) mounted on dash, 36" harness plugged into PBS-I side port
  • Confirm Programming Button stashed accessibly for tag-learn / Emergency Bypass PIN entry

Phase 2: Brake System

Pre-Install Fab + Bench Test

  • Bench test donor iBooster: apply 12V ignition signal, verify motor cycles and pedal rod assists
  • Discard factory Honda master cylinder
  • Install Back Bay Customs adapter + Wilwood 260-15542 MC (1.00" bore) onto iBooster (pushrod pre-set)
  • Mock up donor bracket + iBooster + Wilwood MC assembly against LJ firewall (cardboard/3D-print) - verify engine-bay clearance BEFORE drilling
  • Drill LJ firewall: 4× M8 clearance holes (60×80mm pattern, 80mm vertical) + 62mm center bore (factory booster holes abandoned)
  • Mock up reservoir standoff location 4-6" above MC flange, verify hood clearance

Brake Pedal Swap

  • Remove factory manual-trans pedal assembly (clutch + brake)
  • Verify donor 03-06 auto pedal: stop-lamp switch + clip present, pushrod hole bushing OK, arm not bent
  • Install 03-06 auto brake pedal assembly (BTSI boss left empty)
  • Reconnect stop-lamp switch wiring: PMU In 2, Pin 15 crank-chain tap, Turbolamik brake input
  • Plug clutch master cylinder firewall hole (~1.25" block-off plate or weld closure)
  • Bench-measure pedal pivot-to-pushrod distance vs factory manual pedal (confirm pedal ratio — geometry/travel check for MC stroke headroom + iBooster rod travel, not a feel-tuning step)
  • Re-measure iBooster pushrod length after pedal install; adjust per harness vendor instructions before bleeding

iBooster Installation

  • Confirm factory vacuum brake booster removed
  • Confirm custom firewall bracket installed at factory booster location
  • Confirm iBooster + Wilwood MC assembly mounted to firewall bracket
  • Confirm iBooster mounting bolts torqued to 16.5 Nm (12 ft-lb) - 2x nyloc nuts
  • Confirm secondary front support bracket installed (cantilever brace)
  • Confirm Wilwood 250-16393 dual bracket + 2× 260-16392 reservoirs mounted on standoff
  • Confirm 2× Wilwood 220-12993 flexlines installed: reservoir (-3 AN) → MC (11/16-20)
  • Confirm brake hardlines routed from Wilwood MC to front/rear brakes
  • Confirm iBooster wiring harness connected (Tulay's or EVcreate, per selection)
  • Confirm iBooster main power connected (10 AWG red from PMU OUT1+10)
  • Confirm iBooster ignition signal connected (20 AWG green from PMU OUT19)
  • Confirm iBooster ground connected to engine bay ground bus stud 7 (10 AWG black)
  • Bleed brake system; verify no leaks at flexlines, MC ports, or hardline unions

Phase 3: Grid Heater

  • Confirm ECM pins 46/21 wired to grid heater relay coil (Cummins 5467024)
  • Confirm fusible link installed from START battery+ to grid heater relay
  • Confirm grid heater relay ground connected to START battery- or NEGATIVE bus
  • Confirm grid heater relay mounted in engine bay near intake manifold
  • Verify grid heater element resistance ~0.15Ω (confirms 80A @ 12V design)

Phase 4: HVAC

  • Confirm factory TJ HVAC system complete and functional
  • Confirm vacuum system installed: R2.8 manifold → check valve → reservoir → firewall → dash
  • Verify vacuum system holds vacuum (no leaks)

Phase 5: Wipers

  • Confirm WS-51C wiper controller mounted in dash
  • Confirm PMU OUT11 connected to WS-51C power input (14 AWG)
  • Confirm WS-51C ground connected to firewall ground (14 AWG)
  • Confirm WS-51C low/high outputs connected to factory wiper motor
  • Confirm wiper motor park switch connected to WS-51C park input
  • Confirm WS-51C washer output connected to factory washer pump

Phase 6: Radiator Fan

  • Confirm GM 84100128 fan mounted to radiator shroud
  • Confirm PMU OUT2+3+4 connected to fan motor (4 AWG)
  • Confirm fan ground connected to engine bay ground bus (4 AWG)
  • Confirm PMU programmed with temperature-based PWM control

Phase 7: Horn

  • Confirm PIAA 85115 horns mounted in engine bay
  • Confirm PMU OUT18 connected to horns (14 AWG)
  • Confirm horns grounded to engine bay ground bus (Stud 6)
  • Confirm horn button trigger wire routed through firewall to PMU In 1
  • Confirm PMU programmed: In 1 closes → OUT18 activates

Phase 8: Runaway Protection

Catch Can Installation

  • Confirm Mishimoto MMOCC-UB bracket mounted to selected engine bay location (TBD - intake side, away from exhaust)
  • Confirm MMOCC-CBT catch can installed vertically with petcock at bottom
  • Confirm 5/8" hose from R2.8 valve cover breather to catch can INLET (worm clamps both ends)
  • Confirm 5/8" hose from catch can OUTLET to turbo inlet (worm clamps both ends)
  • Verify catch can petcock closed before first engine start
  • Verify no hose chafing against engine, exhaust, or moving parts

AMOT Air Shutoff Installation

  • Confirm AMOT 4261M02A027-AA installed in pre-turbo intake tract (between air filter outlet and turbo inlet)
  • Confirm NPT-to-hose adapters secure on both AMOT ports
  • Confirm AMOT butterfly cocks fully open and latches; verify lever orientation matches cable pull direction
  • Confirm intake clamps torqued on both sides of AMOT (no boost or vacuum leaks)
  • Confirm AMOT body oriented so the trip lever clears engine bay obstructions through full motion

Cable and T-Handle Installation

  • Confirm Midwest 30-144-TTL-BH-3 T-handle mounted at selected dash location (TBD)
  • Confirm cable conduit passes through dedicated firewall grommet (TBD - must not share with other cables)
  • Confirm cable secured every 12" with adel clamps; no sharp bends (≥6" radius)
  • Confirm cable end attaches to AMOT trip lever; pull stroke ≥0.5" past trip point
  • Confirm T-handle sits flush against dash bezel when AMOT is cocked open
  • Confirm T-handle is labeled EMERGENCY ENGINE SHUTOFF — PULL TO STOP

Phase 9: Testing

iBooster Testing

  • Verify 12V CONSTANT at iBooster main power (ignition OFF)
  • Verify 12V CONSTANT at iBooster main power (ignition ON)
  • Verify 12V at iBooster ignition signal (ignition RUN only)
  • Verify iBooster ground continuity <0.1Ω to battery negative
  • Verify brake pedal feel with iBooster powered
  • Verify fail-safe mode works (disconnect ignition signal, confirm basic assist)
  • Verify standby current ~12mA (ignition OFF)
  • Road test: light braking, hard braking, engine-off coasting

HVAC Testing

  • Verify temperature control (hot/cold blend)
  • Verify mode control (defrost/vent/floor)
  • Verify blower speeds (all settings)
  • Verify A/C clutch engagement
  • Verify heater output

Wiper Testing

  • Verify wiper speeds: Off / Mist / Delay / Low / High
  • Verify wiper park position (returns to rest)
  • Verify washer pump activates
  • Verify auto-wipe triggers after washer spray

Starter Testing

  • Verify starter does NOT crank when brake pedal is released (PBS-I brake interlock blocks PURPLE START)
  • Verify starter does NOT crank when Start Button is not pressed
  • Verify starter does NOT crank without valid PBS-I iTag fob in range (Start Button LED off)
  • Verify starter cranks when fob + Start Button + brake all asserted (engine off, warm engine - WAIT lamp not lit)
  • Verify cold-start sequence: brake + hold button → WAIT lamp illuminates → starter waits → WAIT extinguishes → starter cranks
  • Verify engine shutoff: brake + 2-second button hold → engine stops
  • Verify Emergency Bypass: with fob absent, Programming Button + 4-digit PIN authorizes start
  • Verify fob auto-arm: 60 seconds after fob leaves range, Start Button has no effect

Grid Heater Testing

  • Verify grid heater activates in cold conditions (<50°F ambient)
  • Verify "Wait to Start" lamp illuminates during preheat

Horn Testing

  • Verify horn sounds when button pressed (ignition OFF)
  • Verify horn sounds when button pressed (ignition ON)

Radiator Fan Testing

  • Verify voltage at fan terminals >13V under load (engine running)
  • Verify fan activates at temperature setpoints
  • Verify inverted duty cycle behavior (high duty = low speed)
  • Tune temperature setpoints for R2.8 under real-world conditions

Runaway Protection Testing

  • Static test: engine OFF, pull T-handle, verify AMOT butterfly snaps fully closed (visual through air filter housing)
  • Reset test: re-cock AMOT manually, push T-handle to flush, verify butterfly returns fully open
  • Cable freedom: pull T-handle through full 3" stroke, verify no binding in conduit
  • Functional test (with engine running at idle, away from people/objects): pull T-handle, verify engine stalls within 2 seconds
  • Catch can drain check: after first 100 miles, drain petcock and inspect for oil collection (confirms PCV flow)
  • Visual inspection: verify catch can hoses, AMOT cable, and conduit show no chafing or heat damage

Reference Documentation