SAVVY OFF ROAD GAS TANK SKID INSTALLATION INSTRUCTIONS

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1 It is best to work with a fuel tank that has the least amount of fuel in it as possible. Thank you for purchasing the best skid on the market. Please follow these instructions and your installation should go easy. Suggested Tool List 1/2" deep socket and ratchet with long extension Torque wrench Angle cutters Lug wrench Jack stands Floor or transmission jack Parts List 22-5/16" x 1" Carriage Bolts 22-5/16" Serrated Flange Nuts 4 each 1/4" - 1-1/2" & 1/4" x 2" Hex Cap Screw 2 each 1/2" dowels Threaded and non-threaded 4 - Stainless steel retaining Straps 6 - Bolt retaining clips (for mounting screws) Preparing Savvy Gas Tank Skid Check to make sure all parts have been included against the enclosed parts list. Un-bolt and remove the mounting flanges & hardware kit from base skid and save the hardware. (they may be used later to replace the OEM crossmember skid mount bolts if necessary) It's time to pick a mounting height. This skid can be mounted at two different heights. Typically, Jeeps without a body lift will mount the skid at the lower height. If you intend to use the higher mounting position for maximum ground clearance, a minimum 1" body lift will be needed. There are two rows of holes in the flanged mounts. The row closest to the lower edge of the flanged mounts will achieve the lower skid location recommended for stock vehicles.

2 After you have picked a mounting height, loosely assemble the skid as shown. The carriage bolts insert from the inside of the skid into the square holes to stop them from spinning when you tighten them. At the back flange, the tank hold down straps will be mounted using the holes at either side of the center pair of holes. The front straps are straight forward from those locations and will correspond to the molded in grooves in the fuel tank. Tip- It's easier to keep the straps straight up and down if you leave their attaching bolts slightly loose until you have the cap screws started in the cross dowels. After you get the cap screws started, then go ahead and torque the strap attachment bolts to 18 ft lbs. This will be done after the tank is installed in the skid. Torque all of the bolts to 18 ft lbs starting with the rows of bolts at the front and back of the skid. Leave the 4 bolts on the 2 sides until last. Ready for stock plastic gas tank

3 Removing Stock Gas Tank Assembly You will need to jack up the vehicle to remove the rear tires, so you should use some acceptable method to prevent the vehicle from rolling that will keep you safe and prevent injury or damage. At this point, the vehicle will need to be raised and supported on by the rear axle on jack stands or similar The wheels can now be removed. Remove the gas cap and then the screws that hold the filler neck into the bezel. Tip- After you remove the gas cap from the bezel, reach up inside the rear fender and re-install it on the filler neck to prevent fuel spillage.

4 Pull out the liners being careful to not damage the plastic push in fasteners, as they will be reused (access to the lines is a lot easier when you remove the liners) Tip- Work the bottom edge of the liner out over the top of the frame towards you and then push the top of the liner inwards to facilitate removal. Depressurize the fuel system according to the Jeep Field Service Manual appropriate to your year model On the It may be necessary to loosen the filler neck clamp at the tank so it can be rotated to swing the vent out of the way as you lower the tank. Cut the tie wraps on the vent hose that hold the axle vent line in place. CAUTION! ON THE 05 AND 06 YEAR MODELS, DO NOT FULLY LOWER TANK FULLY UNTIL YOU DISCONNECT THE FUEL LINE FROM THE PUMP. IF THE SUPPLY LINE PULLS ON THE PLASTIC PUMP FITTING, IT WILL BREAK IT AND CAUSE YOU TO NEED A NEW PUMP ASSEMBLY. AVERAGE COST IS 250 DOLLARS Disconnect all the fuel and emissions related lines from the tank before lowering. The location and quantity vary from vehicle to vehicle, so take care to use some method to identify for later correct re-connection. Some models have a ground strap clipped to the tub lip. Remove it and re-clip it back in place after installing the tank. *Tip: The clips on the emission control and vent lines are a pain the in butt to remove. Breaking one will ruin your day so take care when you do. DO NOT USE ANY TOOLS to disconnect these lines! The trick is to relieve pressure on the clip by pushing the hose/line further into the receptacle and then pushing the release (ie. the blue or green clips) on the clips. See the blue clip on the fuel line output on the image below.

5 Disconnect the fuel pump electrical connection. Late models with connection on the fuel pump will require the tank to be lowered to gain access to the connector. Pictured is a 2006 model and like the 05 year model, the connector is at the fuel pump. Previous year models have the connector at the front left side of the OEM skid attached to tab. Those models can be disconnected before the tank is lowered. *Tip: Electrical connector disconnect is easy. Just slide the red lock over and push hard on the release lever and pull it apart. The early models have the connector by the skid edge. The late model have the connector on the fuel pump. Support gas tank skid assembly for removal in some manner that will allow you to readily lower it. Remove the nuts that hold the skid to the front and back crossmembers including the one right above the tailpipe. The nuts on the tank straps can be removed after the tank is out from under the vehicle. Remove the tank straps or swing them out of the way. Installing the Gas Tank Take gas tank out of factory skid and make sure no debris is on the bottom

6 *Tip- the tank will be a snug fit. It will be easier to get it in place if you lower it straight down without tipping it to one side or the other. Also a wide putty knife can be used like a shoe horn to help the tank slide into the skid. Put the gas tank into Savvy Off Road skid. You may have to push it down with some authority to ensure the tank is fully seated in the skid. Take care not to damage any lines or fittings when you do this. Bring the straps together using the Allen head cap screws and cross dowels. Each strap will use two cross dowels and 1 cap screw. One dowel has a through hole another is threaded. Insert the cap screw through the first and thread it into the second. They should only be tightened until there is enough tension to retain the tank and not so much that the tank is deformed. Take care not to trap or pinch any line under the straps that are not supposed to be there. This varies from across the various year models, so paying attention to the factory straps will give you a good idea of what's appropriate. Check the bolts that hold the skid to the chassis. We have included carriage bolts and retainers to replace them should the originals be damaged or corroded. The carriage bolts are inserted from top. The retainers are then pushed on to keep them in place during the skid install. Slowly lift the gas tank assembly into place (on the late model with the electrical connector on the top of the fuel pump connect it now) Take care not to pinch any of the lines or electrical harness as you're raising the skid. The filler neck will need to be guided up between the frame and tub as you raise the tank. *Tip: Guide the skid until you can get the front two slots over the bolts. Put those two nuts on loosely to stabilize the tank and skid. This will let you focus on lining up the four bolts in the back and make things go a bit easier. You can slowly jack the skid into place and line up the rear bolts taking care not to dislodge them from the crossmember. Install and torque the 6 flange mounting bolts to 18 ft lbs. Re-connect all of the fuel, emission control and vent lines. Remove gas gap and insert filler neck into the bezel. Line up the hole and replace the four screws that hold it to the bezel. Put the gas cap back on.

7 Tie wrap the axle vent hose back in place where it was removed from. On the Rubicon models, there will also be another line for compressor inlet air that will need to be secured in the same manner. On models with the fuel pump connector at the skid, it will need to be secured to the tab on the skid with the rectangular cutout in it. Later models will just use the cut-out to secure the harness. Wheel liners can now be re-installed Finish off the installation by checking for leaks. It may take a moment for the fuel system to re-pressurize, so don't be alarmed if it doesn't start right away. A few key on-off cycles will help to get the fuel up to the fuel rail and re-pressurize the system. This gas tank skid is designed for extreme off road use only! Thank you again for purchasing our gas tank skid!