How to Replace the Manifold Assembly on a Weber Grill

Trouble getting your burners to turn on or off? If so, you likely need a new manifold assembly. The manifold assembly consists of the manifold tube, three valves, the orifices and the mounting hardware. The manifold distributes the gas to each of the grill’s three burners. The valves are built into the manifold, which allows you to adjust the gas from off to full. Common manifold assembly problems include stuck valves, a valve that won't shut off completely, and a plugged valve or orifice.

Let's get started.

REMOVING THE MANIFOLD ASSEMBLY   1. Remove the propane cylinder.

a. Disconnect the propane cylinder from the regulator and hose assembly.

b. Remove the propane cylinder from the grill cabinet.   2. Remove the ignitor.

a. Unscrew the igniter button and remove the battery.

b. Remove the lock ring behind the ignitor.

c. Push the igniter inside the housing.   3. Remove the control knobs.

a. Gently pull the control knobs away from the valves.   4. Remove the cabinet doors.

a. Insert a screwdriver into the small opening located on the upper-inside corner of the cabinet door.

b. Depress the screwdriver to disengage the locking hinge pin and release the cabinet door.

c. Remove the cabinet door from the grill.

d. Repeat this step to remove the second cabinet door.   5. Remove the wind deflector.

a. Remove the screws securing the wind deflector to the control panel.

b. Remove the wind deflector.   6. Remove the control panel.

a. Remove the two screws securing the control panel to the front of the grill.

b. Remove the control panel.   7. Disconnect the heat shield.

a. Remove the (2) two screws securing the heat shield to the manifold (there is one screw on each side of the manifold).   8. Disconnect the propane supply from the manifold.

a. Use an adjustable wrench to loosen the fitting on the manifold.

b. Disconnect the propane supply from the manifold.   9. Remove the manifold.

a. Remove the (2) screws securing the manifold assembly to the grill.

b. Remove the manifold assembly from the front of the grill.   INSTALLING THE NEW MANIFOLD ASSEMBLY   10. Loosen the burner tubes.

a. Remove the grill grates.

b. Remove the flavorizer bars.

c. Remove the screws securing the burner tubes to the shoulder mounts at the back of the grill box.   11. Install the manifold assembly.

a. Install the new manifold assembly onto the grill.

b. Verify that the manifold is correctly positioned beneath/behind the heat shield.

c. Align the burner tubes with the valve stems on the manifold (the valve stems slide into the front portion of the burner tubes).

d. While holding the manifold assembly in position, align the rear tabs of the burner tubes with the shoulder mounts at the back of the grill box.

e. Secure the burner tubes to the shoulder mounts with the screws.

f. Secure the manifold assembly to the grill with the (2) screws.

  REASSEMBLING THE UNIT   12. Reinstall the heat shield.

a. Align the back of the heat shield with the notch on the manifold bracket.

b. Secure the heat shield with the (2) screws.

  13. Reinstall the gas fitting.

a. Thread the gas fitting onto the new manifold assembly.

b. Use an adjustable wrench to tighten the gas fitting.

c. Reinstall the propane cylinder and turn the gas “on.”

d. Use a small brush to apply soapy water to the gas fitting (at the manifold) to verify that no gas leaks exist. (Leaking gas will cause bubbles to form in the soapy water.)

  14. Reinstall the control panel.

a. Install the control panel (the top portion of the control panel attaches to hooks on either side of the frame).

b. Secure the control panel with the screws.

  15. Reinstall the igniter.

a. Install the igniter assembly (from the back of the control panel).

b. Secure the igniter assembly with the locking collar.

c. Install the igniter battery.

d. Install the ignitor button.

  16. Reinstall the wind deflector.

a. Install the wind deflector (the tabs on the front of the wind deflector slide over the metal on the bottom on the control panel).

b. Secure the wind deflector with the screws.

  17. Reinstall the cabinet doors.

a. Align the bottom of the cabinet door with the adjustable hinge.

b. Depress the locking pin lever with a screwdriver.

c. Align the (pin) on the cabinet door with the opening on the grill.

d. Release the locking pin lever to engage the locking pin and secure the cabinet door.

e. Check the doors to determine if hinge adjustments are necessary.

f. Repeat steps to remove the doors and adjust the hinge positions as necessary to ensure the best fit.

  18. Reinstall the control knobs.

a. Align the D-shaped valve stems with the D-shaped openings on the control knobs.

b. Press the control knobs onto the valve stems.

  19. Reinstall the grill grates.

a. Install the flavorizer bars.

b. Install the grill grates.

c. Install the warming rack.