Replace Weber Control Valve – Genesis and Spirit Models After 2010.

by grillrepair on November 16, 2016

Video instructions and written directions with pictures to explain how to remove and replace Weber Genesis and Spirit control valves in models manufactured after 2010.

Weber schematic to show bolt through valves attached to manifold pipe in front of BBQ fire box

Weber schematic to show bolt through valves attached to manifold pipe in front of BBQ fire box

As we can see in this clip from the Weber schematic, Genesis and Spirit models manufactured after 2010 have the control valves in the front of the fire box.    This specification view shows the valves installed across the front of the fire box and attached to the manifold pipe where incoming fuel is distributed to the valves.

This video shows accessing removing and replacing these Genesis and Spirit model Weber control valves:

Although it is not necessary to remove the control panel to replace the Weber control valves, we did so for the video so the camera could see what we were doing.   Unlike previous models these new Spirit and Genesis models have a cover plate under the control panel and we do need to remove this to remove the bolt into the valve from the bottom of the manifold pipe.

weber genesis spirit control valve on manifold with orifice

Weber control valve attached to manifold pipe with replacement orifice and original.

Always make sure fuel is off and disconnected when working on the barbecue grill.

http://www.grill-repair.com/weberparts.html

As shown in the tutorial, with the control valves unbolted from the manifold pipe, the control valve will not be removed from the controls because the stainless steel pipe burner is in the way.   The Weber Genesis and Spirit pipe burners slide onto the control valve inside the control panel.  In the back of the fire box the burner slides over a ridge designed into the cast aluminum of the fire box.  A single bolt into the cast aluminum fire box stops the burner from simply lifting up and sliding off the valve.

Back bolt can be loosened to release burner with or without removing bolt.

Back bolt can be loosened to release burner with or without removing bolt. Be Careful Not To Break Bolt Or Aluminum Casting!

The mounting bolt in the back of the fire box can be removed to slide the burner up and back but the bolt does not have to be completely removed — which helps with not misplacing the bolts!   With the bolt unscrewed a few turns the burner can be rotated and lifted up.  Once the burner is lifted straight up in back the burner can be slid back so the front air shutter slides off the control valve orifice.  The ignition electrode is clipped to the burner so we will typically just slide the burner into the fire box and then lie it down without removing the electrode.  No point in making more work.

Please note — about half the time we have worked on used Weber Spirit and Genesis models manufactured after 2010 with the controls in front as shown here, the bolts and/or casting has cracked and broken.    Several times the simple act of very slowly unscrewing this burner bolt will cause the bolt or the cast aluminum to break so be careful.  Fortunately the burner will install and stay in place without the bolt if necessary.

Weber schematic burner slides onto control valve and orifice

Weber schematic. Burner slides through fire box and onto control valve and orifice. Burner can slide off valve without removing burner or igniter electrode to access orifice and valve.

To remove the control valve after unscrewing the lower bolt through the bottom of the manifold, we need to unscrew the back burner bolt and lift up the back of the burner to make room to slide the burner back so the front of the burner slides off the control valve orifice inside the control panel.    With the burner out of the way, the valve will lift off the manifold pipe.   As shown in the Weber schematic, we do not need to remove the burner from the barbecue fire box; we slide the burner into the fire box and then lie it to the side to clear the valve.  Although it is not a lot of work to unclip the electrode and then re attach the ignition, there is nothing to gain by creating extra work.

From inside the fire box we see the burner slides onto the orifice and valve.

From inside the fire box we see the burner slides onto the orifice and valve.

This image shows our point of view as though we are inside the barbecue grill firebox looking at the control valve inside the control panel, attached to the manifold gas pipe.    The tip of the valve is the orifice which is where the air shutter in the front of the pipe burner slides on to the control valve.   Gas flows through the restricted opening of the orifice into the section of the burner that is open to allow air to be pulled into the burner to mix with the fuel so the fuel burn properly mixed emitting through burner ports.

Control valve bolts through Weber manifold pipe

Control valve bolts through Weber manifold pipe

Since 2010 when the Spirit and Genesis BBQ models suffered more changes than any other combined period of time in Weber history these control valves are installed across the front of the fire box just like a lot of more common barbecue models.

Majestic Grill Parts stocks barbecue grill replacement parts, repairs barbecues and ships replacement barbeque parts all over the world.  Without making any kind of a judgement call I can honestly say we sell more of the control valves for post-2010 models than we ship control valves used in the 30 years of models preceding these new designs by Weber.  Even though these models have existed for a very short period of time compared to the total decades of Genesis and Spirit models, the control valves mounted on the right side of the fire box are needed for repairs A Lot Less than these new front-mounted bolt through control valves.

Consumer demand is what led to this blog post tutorial to help with the control valves being replaced.

Majestic Grill Parts hopes this has been useful for your own repairs.  In these images we’re showing a lot of new parts on clean surfaces but this is not the case when repairing used barbeques.  Please Always Make Sure To Clean The Maniofld Pipe And Check The Valve Gasket Seals Above And Below The Manifold Pipe.  One single speck of dirt can cause a dangerous gas leak so please clean the manifold before reinstalling a new valve and leak check the valve before use.

Just like adjusting the air shutter on the burner, checking for leaks means reassembling the entire barbecue and attaching the fuel connection Before reinstalling the cover plate under the control panel.  Install the cover Plate After adjusting the air shutter and checking the control valve for any leaks.

If you have Any questions or Any concerns about repairs, replacement parts, how to check, adjust, repair or replace anything at all, Please Contact Majestic Grill Parts for assistance.

954-2-GRILL-2

Service@Grill-Repair.com

These Control Valves are available at:

http://www.grill-repair.com/weberparts.html

 

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