Skip to content

Section 2: Engine Systems - Installation Checklist

Organized by installation order for efficient build workflow.

Procurement

iBooster

  • Source Bosch iBooster Gen 2 unit (Tesla Model 3 donor)
  • Source Gen 2 master cylinder (Tesla Model 3)
  • Order wiring harness from Tulay's Wire Werks

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 PMU OUT24 (Ignition Authorize) routed through firewall to dash push-button supply
  • Confirm push-button output (cabin) wired in series with brake pedal switch start tap
  • Confirm gated start signal routed through firewall Pin 15 → P/N relay contact in engine bay
  • Confirm P/N interlock relay coil driven by Turbolamik P/N aux output
  • Confirm engine-running lockout relay coil sensed from alternator B+ via filter circuit
  • Confirm engine-running lockout relay NC contacts in series with Cole Hersee coil+
  • Confirm Cole Hersee coil- grounded to engine bay ground bus
  • Confirm ECM ignition relay coil driven by PMU OUT24 (parallel to crank chain supply)
  • Confirm Boomerang Bullet 230 mounted, powered (CONSTANT), and output to PMU In 4
  • Confirm hidden bypass toggle installed (battery+ via 5A fuse → ECM relay coil)

Phase 2: Brake System

iBooster Installation

  • Confirm factory vacuum brake booster removed
  • Confirm iBooster Gen 2 mounted in factory brake booster location
  • Confirm iBooster mounting bolts torqued to 16.5 Nm (12 ft-lb) - 2x nyloc nuts
  • Confirm Gen 2 master cylinder installed
  • Confirm brake lines routed from master cylinder to front/rear brakes
  • Confirm iBooster wiring harness connected per Tulay's diagram
  • 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 firewall ground stud (10 AWG black)

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 with shifter in R, D, or manual gates (P/N interlock relay open)
  • Verify starter does NOT crank when brake pedal is released (brake interlock open)
  • Verify starter does NOT crank when push-button is not pressed
  • Verify starter does NOT crank without Boomerang fob present (PMU blocks OUT24 assertion)
  • Verify starter cranks when fob + push-button + brake + P/N all asserted (engine off)
  • Verify engine-running lockout opens once alternator output > 13V (no Bendix re-engagement)
  • Verify push-button press while engine running kills the engine (OUT24 de-asserts, ECM off)
  • Verify hidden bypass toggle powers ECM ignition relay independent of PMU
  • Verify Boomerang fob lost while running does NOT kill the engine (PMU stay-on logic)

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