Gas Grill Valve Orifice Cleaning and Repair
Step-by-step guide made from Indy Farm Life's YouTube video.
Diagnose and repair a gas grill that won't light or has a low flame by removing the front control panel and disassembling the internal burner gas valves. Clear grease buildup from the tiny valve orifices using solvent and compressed air to restore proper gas flow.
The full step-by-step Spetz Specs for this project (every part, size, diagram and step, free): Gas Grill Valve Orifice Cleaning and Repair Spetz Specs.
- Difficulty: beginner
Disclaimer
- This project involves disassembling propane gas grill valves and manifold components. Always disconnect and remove the propane tank before starting, check all connections for gas leaks after reassembly, follow your grill manufacturer's instructions, and consult a qualified technician if you are unsure how to service gas components safely.
Safety
- Disconnect and remove the propane tank completely before servicing or disassembling any gas grill valves or manifold components.
- Wear eye protection when spraying aerosol brake cleaner, degreaser, or compressed air through small valve orifices.
Must know before you build
- Keep one burner valve fully assembled as a reference for spring and stop alignment.
- Open propane tank valve slowly to avoid tripping the regulator's safety stop valve.
- Avoid replacing the gas regulator; often, the actual issue is a clogged burner valve orifice.
- Use WD-40 or brake cleaner along with compressed air to break up grease clogging the valve orifice.
- Blast compressed air through the orifice after solvent to thoroughly clear stubborn grease.
- Disconnect and completely remove the propane tank before disassembling any grill components.
Tools
- Phillips screwdriver (hand screwdriver, Phillips head)
- Cordless drill/driver (power drill/driver, DeWalt, XR, 20V Max, 4Ah battery, Phillips bit) (optional)
- Air compressor with blow nozzle (air compressor) (optional)
Materials
- WD-40 or brake cleaner (1 can, aerosol degreaser / solvent, WD-40)
Step by step
Step 1: Remove the Control Knobs and Front Face Plate
Pull off the burner control knobs, unscrew the knob bezels and side mounting screws, and detach the front face plate and igniter wires.
- Pull off the burner control knobs. Pull all five burner control knobs straight off the front valve stems and set them aside.
- Unscrew and remove the knob bezels. Remove the two Phillips screws inside each control knob bezel using a screwdriver or cordless drill/driver, then lift off all the round bezels.
- Tip: Switch to a cordless drill/driver to quickly back out all the bezel screws across the front panel.
- Remove the face plate and disconnect igniter wires. Unscrew the three mounting screws on the back of each end panel, pull the front face plate forward off the valve stems, and unplug the igniter wires from the back of the igniter module.
- Tip: Check behind the side shelves where the end panels meet the front face plate for hidden mounting screws.
- Common mistake: Pulling the front control panel completely away without first unplugging the attached igniter wires.
Step 2: Remove the Gas Valve and Inspect the Orifice
Unscrew the gas valve assembly from the manifold crossover tube and inspect the tiny orifice at the tip for grease buildup.
- Remove the front valve stem cap and spring. Unscrew the two small Phillips screws securing the front valve stem cap, pull off the cap with its internal locking stops, and remove the small spring inside.
- Tip: Work on one valve at a time and leave another valve untouched as a factory reference, or take a quick video before disassembling.
- Common mistake: Disassembling all the burner valves at once without keeping one intact as a visual reference for how the spring and stops align.
- Unclamp the saddle valve body from the crossover tube. Pull the manifold crossover tube forward, unscrew the clamping screw on the saddle bracket, and detach the rear valve body from the feed hole in the crossover tube.
- Inspect the orifice at the tip of the valve. Examine the tiny pinhole orifice at the back tip of the removed valve body for grease buildup blocking gas flow.
- Tip: To clear a clogged orifice, spray WD-40 or brake cleaner into the removed valve body and blast compressed air through the valve with an air compressor nozzle until air flows freely.