Replacing the burner on a gas grill is an easy and cost-effective fix for older grills that are demonstrating inconsistent or nonexistent flame patterns.
Step 1: Turn off the propane and disconnect the regulator hose from the propane tank. Detach the tank from its mounting brackets and remove the tank from the grill.
Step 2: Remove the cooking grates and the heat-diffusing plates above the gas burner. Newer grills are equipped with heat diffusers instead of lava rocks or briquettes. If the grill has rocks or briquettes, remove those and then remove the grate they rest on.
Step 3: Once the grill burner is exposed, check to see how it is installed. Adjustable rod burners will typically be held in place with a screw, while H-shaped and single burners usually rest atop mounting brackets or feet. Many burners connect to the gas control valves with flexible venturi tubes, while rod-type burners typically slip directly onto the gas orifices.
Step 4: Disconnect the venturi tube or rod type burner from the gas control valve by removing the wire, clip or hitch pin and gently pulling the end of the tube back off the valve orifice.
Step 5: Remove the burner and take it, along with the manufacturer name and model number of the grill, to your local hardware store. Purchase a universal burner that looks similar or order an exact manufacturer’s replacement burner. The universal burners are more cost-effective, but may not work as well on more-expensive gas grills.
Step 6: With the burner removed, take advantage of the opportunity to clean the inside of the grill. Sweep or vacuum out any loose debris and use a wire brush to remove excess rust and grease. Use a high-pressure hose nozzle and wire brush to clean the cooking grates, diffusing plates, briquettes, rocks and/or rock grates.
Step 7: Assemble the new burner, following the manufacturer’s instructions. Be careful with the flexible venturi tubes. They are easy to damage and will render the new burner inoperable if they become torn or kinked.
Step 8: Install the new burner into position and slide the connecting end onto the gas valve orifice. Properly secure it into place as before.
Step 9: Reattach the propane tank and test the burner to make sure everything is functioning properly. Make any necessary adjustments before reinstalling the remaining grill parts.