Grill Repair: Burners

Gas Control Valves & Manifolds

The control center of your grilling universe, giving you the power to dial up the heat, turn down the flame, and take charge of your culinary destiny.

Control Valves: The control valves supply and regulate the gas flow to the burner. These valves have a spring loaded locking feature and are designed to lock into place when the valve is in the OFF position. The valve must be depressed by pushing in the control knob while turning to the ON position.

Valve Lock not releasing? If a problem occurs with the valve lock not releasing, check that the valve stem extends sufficiently from the control panel. Over time and use, attachment points may slowly bend out of shape and not allowing full depression of the control knob which releases the locking device.

Repair parts: We carry individual replacement control valves for some grill models as well as complete manifold assemblies that contain the control valves. Unfortunately, individual repair parts for control valves are not available. Valve configuration varies widely and must be replaced specifically for your make and model of gas grill.

Barbecues with gas: Long before people started grilling with gas, in the early 1950s George Stephen, Sr. cut a metal buoy in half, added vents and legs, and created the first production kettle-shaped grill for wood and charcoal.

Scroll down for Gas Grill Manifold maintenance

Gas Control Valve Oriface Care

Valve Oriface Cleaning

The valve orifice is an integral part of the control valve. Orifices on the valves will sometimes plug from either insects invading through the venturi or from debris inside the supply line. Orifices can be removed for cleaning. Use an orifice cleaning tool or small wire to clear orifice hole. Use caution not to scratch or damage the orifice hole. Do not operate grill without orifice in place. This poses an extremely dangerous fire hazard.

Gas Valve Manifold Diagram

Orifice Size: The orifice, in conjunction with the control valve, acts to regulate and restrict the amount of gas delivered to the burner. The hole size in the orifice varies by the gas supply pressure and by the BTU rating of the burner. Grills equipped for LP gas operate at a much higher gas pressure and therefore have a smaller size orifice.

Control Knobs

Control knobs vary greatly between grill brands. The variances are the knob shaft length, clockwise and counter clockwise bezel, and the OFF position. An incorrect shaft length can prevent the ability to “push-to-turn”. Original equipment knobs grarantee a proper fit and indication. Universal replacement knobs are available that can be set up for most brand grills.

Control Valve Maintenance

Stuck with a Sticky Valve?

Clean and lubricate Control Valves: For those DIY’ers, gather a few products and tools and set your gas grill dials free! Grab a Philips screwdriver, automotive brake cleaner and a bit of brake grease, and get those knobs turning like new.

10 Steps to Fix a Grill Valve

Disconnect Gas Line before you begin!
Below is information regarding an older Weber Genesis valve, but the same information could apply to a variety of valves.

1: Remove Housing

Remove facia and expose valves Disconnect gas line. Then, remove panel housing to expose the valve bodies.

2: Disassemble

Dissasemble valveRemove the screws that hold the valve together.

3: Remove Cap

Remove facia and expose valvesRemove the control cap. Set the spring aside.

4: Remove Valve

Dissasemble valvePull out the cone valve and clean with brake cleaner.

5: Grease Valve

Remove facia and expose valvesAfter cleaning, apply a very thin coating of grease to the valve.

6: Clean Valve Body

Dissasemble valveApply brake cleaner to a Q-Tip, and swab body until clean. Replace the cone valve back into body, along with spring.

7: Remove control Stem

Remove facia and expose valvesPush the stem through the valve cap, and clean the stem with brake cleaner.

8: Clean Valve Cap

Dissasemble valveApply brake cleaner to a Q-Tip, and swab inside the cap where surfaces mate.

9: Grease the Stem

Remove facia and expose valvesApply a light coat of brake grease to valve stem where it seats. Place the Stem back through the cap.

10: Reinstall Cap

Dissasemble valveAlign the stem into the cone valve, and reassemble. Don’t forget the spring! Repeat the process for each valve.