VELOSSA TECH LIT KIT Intake Ford Fusion BIG MOUTH “LIT KIT” Ram Air Intake Snorkel Installation Guide

VELOSSA TECH LIT KIT Intake Ford Fusion BIG MOUTH “LIT KIT” Ram Air Intake Snorkel

Kit Contents (Full Kit)

Please review this entire 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 (LIT Flare Only)

‘If you already own the Velossa Tech GEN 4 Fusion BIG MOUTH, skip to slide 21 to see install and wiring instructions.

Recommended Tools

Flathead screwdriver or dental pick

| 3mm drive Allen wrench| 8mm box wrench (ratcheting if possible)| Cut off wheel or flat head style wire cutters, either may work|

7mm, 8mm and 10mm sockets and driver

---|---|---|---|---

Stock Components Removal

Remove the clips and screws holding down the radiator cover.
Use a flat head 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 prior to 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.

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, 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 flat head snippers to remove the ribs, try to get them to be as flush as the base material as possible.

Once you have trimmed the ribs and the tabs, you should be left with an opening that is square (close to it) in shape. It doesn’t have to be exact.

Installation

Place the main body spacer over the cowl opening. 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 in 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.

Install the LIT BIG MOUTH Flare

SKIP THIS SLIDE IF YOU PURCHASED A FULL LIT KIT
If you purchased a LIT flare-only and already have a Gen 4 BIG MOUTH. Remove old flare and install the LIT flare with the 4 screws as shown. Install with LED cable facing the driver side

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. Install with LED cable exiting towards the driver side of the vehicle. Do not stress the LED power cable. Read next slides.

Wire Management

Thoroughly clean a small section of the crash bar and place the cable clip onto it to secure the cable. Avoid wire strain and tight bends.

Wiring Harness

Wiring Harness Schematic

Wire Management

Locate this area underneath the driver side headlight. Use two of the supplied 8” zip ties to fasten the controller; the higher it is placed, the better.
One zip tie should go through the Bluetooth Controller mounting eye.

Zip tie the bundle of red wire from the power connector as shown, leaving ~20” of free wire. Connect the grey power connectors. Leave some slack to prevent wire strain.

Route both wires from the power connector up through the side of the headlight into the engine bay. Ground the circuit using the indicated bolt and connect the red wire to the toggle switch as shown in the Wiring Harness Schematic.

Zip tie the toggle switch to the hood latch casing shown using an 8” zip tie.
Run the zip tie through the small fins of the toggle switch to prevent it from sliding.

Zip tie the bundle of red wire from the positive cable as shown, leaving ~30” of free wire. Connect to the toggle switch as shown in the Wiring Harness Schematic. Leave some slack to prevent wire strain.

LIT KIT Power

Power the Lit Kit by fastening the ring terminal to the battery using the OEM lock nut. Tuck away the excess wire.

Plug in the LED power cable as shown (left). Next, guide the 16” zip tie through the indicated hole in order to neatly fasten the loose cables and connectors. It is important that the grey power connector is oriented as such to not strain its wires and that it is fastened at the center of the connector. DO NOT STRAIN CABLES.

Wiring the LIT KIT

Optional: you may ground the toggle switch LED using the short black wire.
Refer to the Wiring Harness Schematic.

Phone App

Download the Diode Dynamics app and connect via Bluetooth.
Re-install the bumper in the reverse order and installation is complete.

How to connect to the app:

1. After installing the app from the app store, open the app on your device.
2. Cycle the power to the Bluetooth controller by unplugging it and plugging it back in or flick the power switch and wait a few seconds, then turn it back on
3.  Wait for the app to detect the controller, it will pop up on the app screen as a Bluetooth controller. If necessary, cycle the power once more to refresh the controller.
4. Once the controller shows up on the app, click it and connect. You have 30 seconds to select the controller once it shows up on the app. After 30 second you will need to refresh again to detect the controller again.
5. Note that if you mounted your controller behind a lot of metal components, this may degrade the signal and range.

Finalize

Re-install bumper in reverse order and enjoy!

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