Weber barbecue grills had the same design for several decades before the major changes in 2007. Since 2007 there has been a major change every year as Weber seems to have become addicted to making new features for its bbq grill models. The Weber models and features have evolved more in the past 3 years then the previous thirty years.
New Weber barbeque grills have finally moved away from the traditional piezo ignition in use for the past three decades. Although it is reassuring to hear that module clicking away like a miniature machine gun the battery modules do not live as long as the old piezo igniters. I have repaired Weber BBQ grills that were over twenty years old and the igniters still functioned. A battery operated module will not live that long. Because the new Weber gas grills are all using battery operated ignition modules, at some point the igniter module and the electrode will need to be repaired. The information below will ensure a successful and safe Weber gas barbecue grill repair.
The module defined is the item that has the button/switch. The module holds the battery and convert the battery into a transferred charge to spark at the electrode. The electrode is like a small spark plug and the electrode mounts near the burner to allow the spark to light the gas emitted from the burner.
Weber Genesis and Spirit barbecues use a “cross-over” grill ignition system. The Weber BBQ cross-over ignition system means that instead of having an electrode mounted over each burner there is one electrode mounted to the gas grill firewall above the front burner only. The electrode is mounted on the front right corner and an extra “cross-over” burner runs perpendicular to the other burners on the far left side of the barbeque. This way although gas comes through all two or three burners only the front burner will ignite. The flames will run along the burner fro right to left and at the far left side of the bbq flame will travel across the cross-over burner to ignite the other barbeque burners.
Before beginning your Weber gas grill igniter repair make certain the shroud is down and the casters are locked. Remove the button and the battery from the module where it sticks up on the control panel.
Using a flat head screwdriver press against one of the tabs on the side of the igniter module from the top of the barbecue control panel allowing it to release from its locked position. Be careful not to scratch the stainless steel control panel.
Push down the igniter module neck while releasing the remaining tab. Remove the igniter module from below the barbeque control panel assembly.
Remover the wires from the bottom of the old gas grill module. Attach the wires to the new replacement module.
The heat shield on the new gas grill parts replacement module should be positioned towards the barbecue firebox. The heat shield is there to protect the electronics from the grilling temperatures.
Make sure the wires and wire clip are attached to the manifold bracket. A manifold in a gas barbeque grill is the pipe that connects the control valves to the gas line. On a Weber Genesis and Spirit module bbq grill the manifold is below the sheet of stainless steel making up the control panel.
From the underside of the control panel push the module up through the hole in the bbq control panel. Keep the module at a slight angle towards the cook box until you see and hear the right side tab snap into place.
Pivot the gas grill igniter module towards the cook box and slide the modules through the control panel until the left side tab clicks into place.
Reconnect the igniter electrode wires to the module if not already attached. Install the battery into the gas bbq grill ignition assembly.
Install the battery and the button onto the battery/module by pushing and turning the button clockwise to lock.
Once the new replacement grill parts are installed please test the module. Push the button and listen for the quick “pop” in rapid succession. Next remove the right side cooking grate and the front flavorizer so the electrode and collector box are visible. Press the module button switch and look for a strong blue arc while listening for the spark. If there is not a strong arc in the collector box replace the battery with a new battery and check the fitting.
The electrode and the gas catcher (collector box) are mounted inside the Weber Genesis and Spirit gas BBQ grill next to the front burner. Remove all of the control knobs above the control panel and unscrew the bolts holding the sheet stainless panel in place. Lift the control panel shelf up and gently pull it away from the Weber gas barbeque grill frame assembly. As the wires become available under the control panel unplug the electrode igniter wires so the control panel is free.
Remove the white wire from the cook box, bend both tabs away with a flat head screwdriver and pull the collector box and electrode through the hole in the gas grill cook box.
Install the new electrode and collector box by following the removal instructions in reverse. Slide the wires through the hole in the cook box. Push down the stainless steel tabs on the collector box – gas catcher to hold the item to the firewall. Attach the wires and test to ensure a good strong blue arc before replacing the flavorizer bar and cooking grates.
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