VELOSSA TECH 2022+ Ford Maverick BIG MOUTH Ram Air Intake Snorkel Installation Guide

VELOSSA TECH 2022+ Ford Maverick BIG MOUTH Ram Air Intake Snorkel

Product Information

The 2022+ Ford Maverick BIG MOUTH is an aftermarket kit designed to enhance the appearance of the vehicle’s front grille. It comes in two variations: Single Kit and Dual Kit. The kit includes various components such as screws, nuts, washers, spline shafts, spacers, AGS simulator brackets, and fastening points.

Kit Contents

Please review this document before attempting installation.
You will need basic hand tools and 2 hours of installation time.

Single Kit Contents

• 2 x M5 x 20mm Cap Screw
• 2 x M5 lock nut
• 2 x M5 large washer

Dual Kit Contents

• 4 x M5 x 20mm Cap Screw
• 4 x M5 lock nut
• 4 x M5 large washers
• 2 x M5 x 25mm Cap Screw
• 1 x M3 x 60mm Cap Screw
• 2 x AGS Spline Shafts (D&P)
• 2 x 5mm Spacer

Product Usage Instructions

1. Before starting the installation process, review the entire document and ensure you have the necessary tools and approximately 2 hours of installation time.
2. To remove the bumper, refer to your vehicle’s specific trim instructions or search online for guidance.
3. Locate the duct and remove it by squeezing the two tabs along the sides and pulling it off.
4. Disconnect the plug located near the hood latch on the backside of the radiator shroud to access the concealed hole behind it.
5. Flex and remove the top five grille shutters on the left half of the assembly. Take precautions to avoid injury and damage to the radiator. These shutters will not be reinstalled, but keep them for future use.
6. If you have the Dual Kit, flex and remove the top five grille shutters on the right half of the assembly as well.
7. Separate the D and P brackets of the AGS Simulator and thread them into the hole closest to the shaft until flush, using spacers if provided.
8. Install the AGS Simulator brackets into the AGS motor, aligning them with their corresponding sides (driver and passenger). Use the provided M3 x 60mm socket head screw to sandwich the bracketstogether. Align the nearest C-shaped opening on the moving AGScarriage with the M5 x 25mm socket screws and thread the screws through until they bottom out.
9. Trim the radiator shroud using a Dremel and a cutoff blade. Follow the referenced images to mark the necessary cut perimeter and make the cut carefully. Take precautions to protect yourself and the radiator.
10. Use a deburring tool or file to clean up the edges left behind from the cut. Ensure there is plenty of clearance between the cut shroud and BIG MOUTH, with no binding or pre-load.
11. Identify the indicated holes for fastening the Big Mouth.
12. Using the provided M5 x 20mm cap screws, washers, and lock nuts, fasten the Big Mouth. Do not overtighten at this point, as minor adjustments may be required for proper orientation.

Please note that these instructions are a summary. Refer to the complete user manual for detailed installation steps and additional information.
Navigating the Manual
This instruction manual lays out how to install both versions of the Ford Maverick BIG MOUTH: single kit (one ram air intake) and dual kit (two ram air intakes).
The single kit contains a passenger body while the dual kit has a passenger side body and a driver side body.
The steps for installing the passenger side body and the driver side body are very similar with a few caveats. The additional steps that are specific only to dual kit owners will be contained in slides that have an orange border. If a slide has an orange border, it is only relevant to those with a dual kit so owners of single kits may omit them.

Installation

1. Stock Components Removal
   It is best to Google “how to remove bumper” for your particular trim. Remove this duct by squeezing the two tabs along sides of the duct at the indicated points and pulling it off.

2. Disconnect Plug
   Disconnect this plug (located near hood latch on the backside of the radiator shroud) to allow access to the hole concealed behind it.

3. Remove Flaps
   For the Big Mouth to fit, the top five grille shutters on the left half of the assembly will need to be removed. This can be done by flexing them enough such that the ends can be freed from their slots. Take precautions to avoid injury and damage to the radiator. These shutters will not be reinstalled but do not discard them .

4. Remove Flaps (Driver Side, Dual Kit Only)
   For the Big Mouth to fit, the top five grille shutters on the right half of the assembly will need to be removed. This can be done by flexing them enough such that the ends can be freed from their slots. Take precautions to avoid injury and damage to the radiator. These shutters will not be reinstalled but do not discard them.

5. AGS Simulator (Dual Kit Only)
   The AGS Simulator brackets were designed to allow the AGS to continue to function with the Dual BIG MOUTH installed. There are two brackets, one is labeled D for driver side and one is labeled P for passenger side. Prepare them for install by undoing the M3 x 60mm socket head screw that is holding the brackets together. Next, thread the M5 x 25mm socket head screws (with donut the spacers on them) into the brackets. Use the hole closest to the shaft of each bracket. Do not thread fully, just enough until the end of the screw is flush as shown.

6. AGS Simulator (Dual Kit Only)
   Install the AGS Simulator brackets into the AGS motor, into their corresponding sides (driver and passenger). It will require some effort, but they are meant to fit very snugly inside the splined receptacle. Use M3 x 60mm socket head screw to sandwich the brackets together. Align the nearest C-shaped opening on the moving AGS carriage with the M5 x 25mm socket screws and thread the screws through until they bottom out.

7. Trim Shroud
   A requirement of the install is the trimming of the radiator shroud with the use of a Dremel and a cutoff blade. Use the references outlined in the images to mark the perimeter of the necessary cut and make the cut carefully. Enlarged versions of these images are provided in the next two slides. Take the necessary precautions to protect yourself and the radiator.

8. Trim Cleanup
   Use a deburring tool or file to clean up the edges left behind from the cut. The final cut should look like the one shown below.

9. Fastening Points
   The indicated holes are the ones that are being used to fasten the Big Mouth .

10. Install Big Mouth
    Use the provided M5 x 20mm cap screws, washers and lock nuts to fasten the Big Mouth. DO NOT OVERTORQUE. It is not advised to tighten fully at this point until the Big Mouth is oriented correctly; the holes are oversized to allow for minor adjustments.
    Bolt heads enters from the rear of the radiator support.

11. Adjust Big Mouth
    Adjust the orientation of the Big Mouth by tightening the screws just enough to allow for minor tweaks. When it is properly positioned, tighten the screws. DO NOT OVERTORQUE.

12. Trim Shroud (Driver Side, Dual Kit Only)
    A requirement of the install is the trimming of the radiator shroud with the use of a Dremel and a cutoff blade. Use the references outlined in the images to mark the perimeter of the necessary cut and make the cut carefully. Enlarged versions of these images are provided in the next two slides. Take the necessary precautions to protect yourself and the radiator.

13. Install Big Mouth (Driver Side, Dual Kit Only)
    Use the remaining M5 x 20mm cap screws, washers and lock nuts to fasten the driver side Big Mouth. DO NOT OVERTORQUE. It is not advised to tighten fully at this point until the Big Mouth is oriented correctly; the holes are oversized to allow for minor adjustments.

14. Adjust Big Mouth (Driver Side, Dual Kit Only)
    Adjust the orientation of the Big Mouth by tightening the screws just enough to allow for minor tweaks. When it is properly positioned, tighten the screws. DO NOT OVERTORQUE.

15. AGS Simulator (Dual Kit Only)
    Before fully bolting the bumper (you may hang the bumper on the vehicle and plug in the headlights), confirm proper installation of the AGS Simulator brackets. First, make sure the servo motor of the AGS motor is connected (located at the top-center of the AGS system). Set up a way to film the AGS flaps or ask another person to witness AGS movement through the grille after turning the vehicle on.

16. Final Assembly Review
    Review the install and make sure nothing is binding or causing any preload on any parts, loosen and retighten if adjustment is necessary.

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