VELOSSA TECH Fusion-Sport-GEN4-BIG Big Mouth Gen 4 Lower Body Ram Air

Intake Snorkel

Product Information

Product Specifications

• Product: Ford Fusion BIG MOUTH Ram Air Intake
• Compatibility: 2013-2020 Ford Fusion models
• Installation Time: Approximately 2 hours
• Tools Required: Flathead screwdriver, dental pick, 3mm drive Allen wrench, 8mm box wrench, cut off wheel or flat head style wire cutters, 7mm, 8mm, and 10mm sockets and driver

Product Usage Instructions

Kit Contents
Ensure you have received the following kit contents:

• Stock Components Removal
  To begin the installation, remove the clips and screws holding down the radiator cover using a flathead screwdriver or dental pick.

• AGS Removal
  Prior to installation, the AGS assembly needs to be removed. Refer to YouTube videos or Forum guides for instructions on bumper removal and unscrewing various fasteners and clips to remove the AGS system.

• Trimming
  Trim some of the ribs located on the radiator cover using a Dremel or cut-off tool. Remove material from the stock opening as indicated in the provided guide.

• Installation
  Place the main body spacer over the cowl opening and then seat the BIG MOUTH, keeping the spacer over the cowl during this step. Drop the BIG MOUTH into the trimmed opening carefully, ensuring it slides in smoothly.

Frequently Asked Questions (FAQ)

• Q: Do I need any special tools for installation?
  A: Basic hand tools like a screwdriver, wrenches, and cutters are required. Specific sizes and types are mentioned in the instructions.

• Q: How long does the installation process take?
  A: The installation typically takes around 2 hours to complete.

Kit Contents

• Please review this document before attempting installation.
• You will need basic hand tools and about 2 hours of installation time.
• Please review the table below and make sure you have received the kit contents.

Kit Contents Qty

10-32 Countersunk Screws| 2

Recommended Tools

Stock Components Removal

Remove the clips and screws holding down the radiator cover. Use a flathead screwdriver or a dental pick.

AGS Removal

• For best instruction on bumper removal, use YouTube videos or Forum guides to guide you on bumper removal.
• Search the term “2017 Fusion Sport or Ford Fusion bumper removal”.
• The AGS assembly will need to be removed before installation. The AGS system can be removed by unscrewing various fasteners and removing clips from both sides and underneath the assembly.
• Underneath the AGS assembly flap are more fasteners, remove them.

Stock Components Removal

Remove the stock inlet tube by removing the fasteners here, using the 8mm box wrench. Do not discard these screws as they will be re-used for installation.

Trimming

• Trimming some of the ribs located on the radiator cover is required for proper fitment of the BIG MOUTH. It is best to use a Dremel or other cut-off tool for this task, although the flat-head snippers may work too. The ribs on top of the radiator support (we call this the egg crate) must be shaved down in certain areas.
• The areas in the next few slides are highlighted to guide you.
• You will need to remove material from the stock opening, and trim the green boxed-out segments shown below.
• There are two more vertical tabs you need to trim using the cut-off wheel or snippers.
• Flatten these ribs using the cut-off tool or snippers.
• An example shown below uses the flathead snippers to remove the ribs and try to get them to be as flush with the base material as possible.
• Once you have trimmed the ribs and the tabs, you should be left with a square opening (close to it) in shape. It doesn’t have to be exact.

Installation

• Place the main body spacer over the cowl opening. The next step will be to seat the BIG MOUTH, keep the spacer over the cowl when performing the next step.
• Once you have completed trimming, you will be able to drop the BIG MOUTH using the following method. READ THIS CAREFULLY.
• Holding the BIG MOUTH main body in your left hand, you should be able to drop it into the trimmed opening you prepared. It should slide in, you might need to squeeze the BIG MOUTH with your left hand to finesse it through.
• Insert the BIG MOUTH (inlet first) into this newly trimmed opening. It may be a little tight, but if there is too much resistance, you need to trim more. You shouldn’t need to force it.
• You should now have the body and spacer in place and LOOSE. The next step is to seat the BIG MOUTH over the cowl lip.
• Seating the BIG MOUTH requires you to visually confirm this one thing. Visually observe that the BIG MOUTH flange is going OVER the cowl lip.
• While you are positioning the flange with your left hand, you may begin to apply pressure to the pressure dot, once the flange clears the cowl, it should fall in easily.
• Insert the 8mm screws you removed from the stock inlet tube and ensure that everything lines up properly before tightening down. The body should not be under too much stress, torque just enough to close the gap between the space and flange.
• Put the BIG MOUTH flare over the main body inlet and line up the holes on the sides, insert the screws, and tighten until snug.

Finalize
Put all intake parts back in reverse order, re-install the bumper, and enjoy!

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