2.2 Brake Booster - Bosch iBooster Gen 2¶
Type: Electric vacuum-independent brake booster
Model: Bosch iBooster Gen 2
Manufacturer: Bosch Mobility
Product Page: Bosch iBooster
Mounting: Factory brake booster location on firewall
Power Source: PMU OUT1+10 (40A main), OUT19 (5A ignition signal)
Wiring Harness: Tulay's Wire Werks Gen 2 Universal Harness
Overview¶
Electromechanical brake booster that eliminates the need for engine vacuum. Required for Cummins R2.8 diesel conversions which produce minimal vacuum.
Donor Vehicle: Tesla Model 3
Specifications¶
- Current: 40A peak (braking), 0.25A idle, 12mA standby
- Mounting Bolt Torque: 16.5 Nm (12 ft-lb) - 2x nyloc nuts, 13mm
- Master Cylinder: Gen 2 specific (not interchangeable with Gen 1)
Wiring¶
| Circuit | Wire Gauge | Source | Destination | Notes |
|---|---|---|---|---|
| Main Power (PMU side) | 12 AWG × 2 | PMU OUT1, OUT10 | Splice near PMU | PMU 2.8mm terminals max 12 AWG |
| Main Power (load side) | 10 AWG | Splice | iBooster main connector | CONSTANT (safety requirement) |
| Ignition Signal | 20 AWG | PMU OUT19 | iBooster ignition input | SWITCHED (ignition RUN) |
| Ground | 10 AWG | iBooster ground | Engine Bay Bus Stud 7 | Same stud as main power ground |
Wire Transition: PMU terminals accept max 12 AWG. Two 12 AWG wires from OUT1 and OUT10 splice into a single 10 AWG wire near the PMU to minimize voltage drop.
See PMU Outputs for complete PMU configuration and thermal analysis.
Installation Resources¶
- Wiring the iBooster - EVcreate
- Installing the iBooster - EVcreate
- iBooster Donor Vehicles - EVcreate
Outstanding Items¶
None - design complete. See installation checklist for build tasks.
Related Documentation¶
- PMU Outputs - OUT1+10 and OUT19 configuration
- Engine Bay Ground Bus - Stud 7 ground connection
- Firewall Ingress - Mounting and wire routing