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Section 2: Engine Systems - Installation Checklist

Organized by installation order for efficient build workflow. Each item is a check-off confirmation — specs and part numbers live in the linked source docs; parts to buy live in the Purchase Tracker.

Phase 1: Starter System

  • Confirm starter motor mounted to engine block
  • Confirm START battery+ → starter battery post
  • Confirm Cole Hersee solenoid mounted on firewall (engine bay side)
  • Confirm starter battery post → Cole Hersee input
  • Confirm Cole Hersee output → starter switch post
  • Confirm PBS-I module mounted under-dash, powered from Critical Cabin PDU
  • Confirm PBS-I PURPLE START → firewall Pin 15 → Cole Hersee coil+
  • Confirm Cole Hersee coil- grounded to engine bay ground bus
  • Confirm PBS-I PINK IGN → cabin ignition bus bar → firewall Pin 12 → ECM 12V + PMU Pin 7
  • Confirm Start Button mounted on dash, harness plugged into PBS-I
  • Confirm Programming Button stashed accessibly for tag-learn / Emergency Bypass

Phase 2: Brake System

Pre-Install Fab + Bench Test

  • Bench test donor iBooster: apply ignition signal, verify motor cycles and pedal rod assists
  • Discard factory Honda master cylinder
  • Install Back Bay Customs adapter + Wilwood MC onto iBooster
  • Mock up iBooster + MC assembly against firewall — verify engine-bay clearance BEFORE drilling
  • Drill firewall for iBooster mounting (factory booster holes abandoned)
  • Mock up reservoir standoff location, verify hood clearance

Brake Pedal Swap

  • Remove factory manual-trans pedal assembly
  • Verify donor auto pedal: stop-lamp switch + clip present, bushing OK, arm not bent
  • Install 03-06 auto brake pedal assembly
  • Reconnect stop-lamp switch wiring: PMU In 2, PBS-I Brake input, Turbolamik brake input (T-tap, cabin splice)
  • Plug clutch master cylinder firewall hole
  • Bench-measure pedal ratio vs factory pedal (confirm MC stroke + iBooster rod travel headroom)
  • Re-measure iBooster pushrod length after pedal install; adjust per harness vendor instructions

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 secondary front support bracket installed
  • Confirm Wilwood dual bracket + reservoirs mounted on standoff
  • Confirm flexlines installed: reservoir → MC
  • Confirm brake hardlines routed from MC to front/rear brakes
  • Confirm iBooster wiring harness connected (TBD #105: Tulay's or EVcreate)
  • Confirm iBooster main power connected (START+ Forward Dist Bus, 50A CB)
  • Confirm iBooster ignition enable connected (Ignition bus Term 5, 7.5A fuse, firewall Pin 18)
  • Confirm iBooster ground connected to engine bay ground bus (dedicated/redundant ground recommended)
  • Bleed brake system; verify no leaks

Phase 3: Grid Heater

  • Confirm ECM pins 46/21 → grid heater relay coil
  • Confirm fusible link from START battery+ to grid heater relay
  • Confirm grid heater relay ground → START battery- or NEGATIVE bus
  • Confirm grid heater relay mounted near intake manifold
  • Verify grid heater element resistance confirms design current (TBD #42)

Phase 4: HVAC

  • Confirm Restomod Air kit model/configuration against order on arrival (TBD #146)
  • Install Restomod Air HVAC kit per included instructions (factory TJ HVAC assembly, vacuum lines, and cable linkage removed)
  • Verify Restomod Air blower draw ≤25A on PMU OUT5
  • Wire control head compressor request → trinary switch → PMU In 9 (verify wire colors against kit diagram)

Phase 5: Wipers

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

Phase 6: Radiator Fan

  • Confirm GM 84100128 fan mounted to radiator shroud
  • Confirm START+ Forward Dist Bus (60A CB) → relay → fan power
  • Confirm Lingenfelter VSFM-002 + coolant sensor installed (sensor P/N + port TBD #134)
  • Confirm fan ground connected to engine bay ground bus
  • Confirm VSFM-002 commands full speed on lost sensor signal (TBD #134)

Phase 7: Horn

  • Confirm PIAA 85115 horns mounted in engine bay
  • Confirm PMU OUT18 → horns
  • Confirm horns grounded to engine bay ground bus
  • Confirm horn button trigger routed through firewall to PMU In 1
  • Confirm PMU programmed: In 1 → OUT18

Phase 8: Runaway Protection

Catch Can Installation

  • Confirm catch can bracket mounted (TBD #58 — intake side, away from exhaust)
  • Confirm catch can installed vertically with petcock at bottom
  • Confirm hose from valve cover breather → catch can INLET
  • Confirm hose from catch can OUTLET → turbo inlet
  • Verify catch can petcock closed before first engine start

AMOT Air Shutoff Installation

  • Confirm AMOT installed in pre-turbo intake tract
  • Confirm NPT-to-hose adapters secure on both AMOT ports
  • Confirm AMOT butterfly cocks open and latches; lever orientation matches cable pull
  • Confirm intake clamps secured (no boost or vacuum leaks)
  • Confirm AMOT body oriented so trip lever clears obstructions through full motion

Cable and T-Handle Installation

  • Confirm T-handle mounted at dash location (TBD #56)
  • Confirm cable conduit passes through dedicated firewall grommet (TBD #57)
  • Confirm cable secured along run; no sharp bends
  • Confirm cable end attaches to AMOT trip lever; pull stroke clears trip point
  • Confirm T-handle sits flush against dash bezel when AMOT is cocked open
  • Confirm T-handle labeled EMERGENCY ENGINE SHUTOFF — PULL TO STOP

Phase 9: Testing

iBooster Testing

  • Verify iBooster main power present (ignition OFF and ON)
  • Verify iBooster ignition signal present (RUN only)
  • Verify iBooster ground continuity to battery negative
  • Verify brake pedal feel with iBooster powered
  • Verify fail-safe mode (disconnect ignition signal, confirm basic assist)
  • Verify iBooster standby current within spec (ignition OFF) — TBD #151: standby spec not yet sourced
  • 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
  • Verify A/C clutch engagement
  • Verify heater output

Wiper Testing

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

Starter Testing

  • Verify starter does NOT crank with brake released (PBS-I brake interlock)
  • Verify starter does NOT crank when Start Button not pressed
  • Verify starter does NOT crank without valid iTag fob in range
  • Verify starter cranks when fob + Start Button + brake all asserted (warm engine)
  • Verify cold-start sequence: IGN on → WAIT lamp illuminates → extinguishes → driver cranks (no auto-gate; driver waits for the lamp)
  • Verify engine shutoff: brake + button hold → engine stops
  • Verify Emergency Bypass: Programming Button + PIN authorizes start with fob absent
  • Verify fob auto-arm after fob leaves range

Grid Heater Testing

  • Verify grid heater activates in cold conditions
  • Verify "Wait to Start" lamp illuminates during preheat

Horn Testing

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

Radiator Fan Testing

  • Verify voltage at fan terminals under load
  • 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
  • Reset test: re-cock AMOT, push T-handle to flush, verify butterfly returns open
  • Cable freedom: pull T-handle through full stroke, verify no binding
  • Functional test (engine idling, clear area): pull T-handle, verify engine stalls
  • Catch can drain check after first 100 miles (confirms PCV flow)

Reference Documentation