November 1, 2016

How to replace a gas grill burner

By Lyle Weischwill
How to replace a gas grill burner

This repair guide gives step-by-step instructions for how to replace a burner on a gas grill in about 15 minutes. If a burner on your grill produces an uneven flame or a flame that is low even when you turn the burner to high heat, first try cleaning it with a wire brush. If the problem persists, or if the burner is obviously damaged, replace it with the manufacturer-approved replacement part that fits your gas grill model.

These basic steps show how to replace a grill burner in common Kenmore, Charbroil, Grand Hall, BBQ-Pro, Nexgrill and Brinkman gas grills.

Quick links
Tools required
Phillips screwdriver
Needle-nose pliers
Work gloves
Repair difficulty
Time required
15 minutes or less
Repair difficulty
Time required
15 minutes or less
Replacing a burner on a gas grill

This video explains how to replace a burner on a gas grill.

Instructions

  1. 01.

    Shut off the gas supply

    Close the shut-off valve on the propane gas tank.

    Tip: Arrows on the tank knob show which way to turn it to open and close the valve.
  2. 02.

    Remove the cooking grate and flame tamer

    Remove the cooking grate and flame tamer from the top of the damaged burner.

    Remove the cooking grate.

    Remove the cooking grate.

  3. 03.

    Remove the burner

    Using needle-nose pliers, pull the cotter pin out of the back of the burner.

    Remove the burner mounting screw.

    Pull the burner back and up to release it from the manifold and remove the burner.

    Remove the burner mounting screw.

    Remove the burner mounting screw.

    Remove the burner.

    Remove the burner.

  4. 04.

    Install the new burner

    Push the new burner into the manifold.

    Reinstall the burner mounting screw.

    Reinstall the cotter pin.

  5. 05.

    Reinstall the cooking grate and flame tamer

    Reinstall the flame tamer over the burner.

    Reinstall the cooking grate.

  6. 06.

    Restore the gas supply

    Open the valve on the propane gas tank.

Warning: Undertaking repairs to appliances can be hazardous. Use the proper tools and safety equipment noted in the guide and follow all instructions. Do not proceed until you are confident that you understand all of the steps and are capable of completing the repair. Some repairs should only be performed by a qualified technician.

Symptoms for gas grills

Choose a symptom to see related gas grill repairs.

Main causes: damaged or dirty flame tamers, corroded firebox, accumulated grease and debris in the grease pan
Main causes: empty fuel tank, tripped flow-limiting device on the pressure regulator, faulty manifold valves, burner tubes not aligned
Main cause: worn wheel
Main causes: clogged burner tubes, cracked insulators on igniter electrodes, wiring failures, bad ignition module, manifold failure
Main causes: nearly empty fuel tank, faulty pressure regulator, burner tube clogs, bad burner tube alignment to gas valves, manifold failure

Repair guides for gas grills

These step-by-step repair guides will help you safely fix what’s broken on your gas grill.

November 1, 2016
By Lyle Weischwill
How to replace a gas grill wheel

Replace a broken or damaged wheel in less than 15 minutes.

Repair difficulty
Time required
 15 minutes or less
November 1, 2016
By Lyle Weischwill
How to replace a gas grill pressure regulator

You can install a new pressure regulator on your gas grill if the pressure regulator won’t let gas flow.

Repair difficulty
Time required
 15 minutes or less
November 1, 2016
By Lyle Weischwill
How to replace a gas grill igniter electrode

Replace the igniter electrode on your gas grill if it won’t light the burner.

Repair difficulty
Time required
 15 minutes or less

Articles and videos for gas grills

Use the advice and tips in these articles and videos to get the most out of your gas grill.

February 1, 2017

How to convert a propane grill to natural gas video

By Sears PartsDirect staff

A conversion kit and a few simple tools are all you need.

February 1, 2017

How to fix uneven heating on a gas grill video

By Sears PartsDirect staff

Clogged or corroded burners and flame tamers could be the problem.

March 1, 2015

Easy DIY gas grill repairs if the burner won't light

By Sears PartsDirect staff

Learn how to diagnose and fix the problem if the gas grill won’t light.