November 1, 2016

How to replace a gas grill pressure regulator

By Lyle Weischwill
How to replace a gas grill pressure regulator

This repair guide gives step-by-step instructions on how to replace the pressure regulator on a gas grill. A defective pressure regulator can prevent the burners from getting enough gas, or any gas at all, and the burners won't ignite. Reset the regulator as described in the owner's manual for your grill. If you’ve already tried to reset the regulator as described in your owner’s manual and the regulator still doesn’t work, replace it with a manufacturer-approved replacement part.

This repair guide and video shows how to replace the pressure regulator in common Kenmore, Charbroil, Weber, KitchenAid, Nexgrill, BBQ-Pro and Brinkman gas grills.

Quick links
Tools required
Wrench set
Work gloves
Repair difficulty
Time required
15 minutes or less
Repair difficulty
Time required
15 minutes or less
Replacing a pressure regulator on a gas grill

This video explains how to replace the pressure regulator 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 open and close the valve.
  2. 02.

    Disconnect the hose from the tank

    Turn the hose coupling nut counterclockwise and release the coupling nut from the propane tank.

    Remove the regulator hose from the tank.

  3. 03.

    Remove the pressure regulator

    Disconnect the hose from the manifold.

    Remove the cotter pin and release the hose from the grill frame.

    Remove the pressure regulator.

    Disconnect the hose from the manifold.

  4. 04.

    Install the new pressure regulator

    Clean the manifold fitting.

    Connect the hose to the manifold fitting and tighten firmly.

    Connect the hose to the grill frame then reinstall the cotter pin.

    Connect the hose to the propane tank. Tighten the hose coupling nut firmly.

  5. 05.

    Restore the gas supply

    Open the valve on the propane gas tank.

  6. 06.

    Check for leaks

    Coat the manifold fitting and tank fitting connections with a soapy solution.

    Look for bubbles that indicate a gas leak on the fitting connections.

    If bubbles appear, shut off the tank valve immediately.

    Tighten the leaking fitting connection.

    Restore the gas supply and retest for leaks.

    Continue the process until you find no connection leaks.

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.

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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.

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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.

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

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