How to Replace a Gas Grill Control Valve

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Knowing how to replace key components of your gas grill extends its lifespan and protects your investment. One essential part that often needs attention is the control valve, which can become stuck or break over time, making your grill less safe and efficient.

The good news? With a little bit of know-how and safety precautions, you can easily replace a gas grill control valve!

In this guide, we’ll explain the role of your gas grill control valve, how to identify when it needs replacing, and provide step-by-step instructions to replace it safely using simple household tools.

In our many years of troubleshooting gas grill issues, we’ve had to replace a few gas grill control valves in our time. While it might seem daunting, it’s actually easier than you might think.

Read on to find out how it’s done.

What Is a Gas Control Valve?

A gas control valve is the part of your grill that regulates how much gas flows into the burner from the gas tank or natural gas supply.

The gas control valve is typically located inside the front panel of the grill. It is connected to the main gas line, which feeds fuel from the propane tank or natural gas line.

It typically has a small, cylindrical shape with a valve stem that protrudes out, allowing it to be turned by the grill’s control knob. The valve will have two main connections: one for the gas supply line and one for the burner. These connections may look like small pipes or threaded fittings.

Each burner on the grill usually has its own control valve, allowing for individual adjustment of the flame. These valves are linked to the control knobs on the outside of the grill, which you turn to adjust the heat settings.

This setup makes it easy for you to control the amount of gas flowing to each burner, making it a cinch to set your desired temperature.

Finally, gas control valves on a gas grill typically have an orifice attached. The orifice is a small, precisely sized opening that controls just how much gas is allowed to flow into the burner.

What Is an Orifice?

An orifice is a grill part with a small opening that works with the gas control valve to regulate the amount of gas that flows into the burner.

Different sizes of orifices are used for different types of gas (e.g., propane or natural gas) and to achieve specific heat output levels. This means that using the correct orifice size is important for proper grill performance and safety.

Always make sure to use the correct sized orifice when replacing a gas valve.

When to Replace a Gas Grill Valve

A gas grill valve will need to be replaced if it’s either frozen or broken. You can tell this is happening when the grease inside the valve overheats, preventing it from moving smoothly.

Here are some indicators that it might be time to replace a gas grill valve:

  • Sticking Valve: If the valve is difficult to turn or becomes stuck, it may need replacement to ensure proper control of the gas flow.
  • Leaking Gas: If you detect the smell of gas near the valve, or if you notice bubbles forming when applying a soapy water solution, the valve might be leaking and should be replaced immediately for safety reasons.
  • Inconsistent Flame: If the flame from the burner is uneven or flickers, and you’ve already cleaned the burner and checked the gas supply, the valve might be faulty.
  • Corroded or Damaged Valve: Visible corrosion, rust, or damage to the valve can indicate that it needs to be replaced.
  • Broken Knob or Stem: If the control knob or the valve stem is damaged or broken, it can affect your ability to control the gas flow accurately, signaling a need for replacement.

Eventually, these valves can become stuck in place, and if you try to force them to move, they can break. If this happens, there is no option to repair the valves, only to replace them.

How to Replace a Gas Grill Valve

To replace your gas grill’s valve, first, make sure your propane tank or natural gas supply is fully closed. Detach the regulator from the gas supply.

Next, pull the ignition knobs on the front of your grill straight out. They should come off easily, revealing the valve stem and adjustment screw underneath.

Once those stems are visible, remove your grill’s control panel. You’ll want to pay extra attention here to make sure you’re not pulling or damaging any wires. Every grill is different so make sure to read your owner’s manual for directions.

After the control panel is off and the valves are exposed, unscrew the clip that holds the valve to the manifold. This will detach them from the manifold, allowing you to remove the old valve and replace it with a new one.

Use the Thread Seal Tape onto the threads before securing the new valves. Once the valves have been replaced, reconnect the gas and use the soapy water solution to check for leaks. If there are no leaks, reinstall the control panel and control knobs and you’re good to go.

Need help finding the right control valve for your grill? Check out this guide for helpful tips: How to Find the Right Replacement Parts for Gas Grills

How to Maintain a Gas Grill Valve Knob

A little bit of routine maintenance can go a long way in ensuring your valve knobs work great and won’t have to be replaced.

First, use a 50/50 mix of dish soap and warm water and perform a leak test on the hose connection near the valve to make sure it’s tight.

Next, to thoroughly clean your valves, separate the hex head from the orifices, and then clean the holes.

Check the inner part of the valve through the gas jets, and use a small piece of wire or a toothpick to clear out any spider webs or debris.

After you’ve cleaned the valves, uninstall the orifices and tighten them completely. To make sure they’re tight, use that mix of water and soap to perform another quick leak test.

How to Clean the Orifice on a Gas Grill Valve

Like any other part of your grill, orifices can occasionally be clogged by debris or insects, so regular cleaning is helpful for keeping your grill running smoothly.

To clean your orifice, first remove it from the grill, then use a small wire or dedicated tool to clear out the hole before reinstalling it.

Be sure not to turn on your grill while cleaning the orifice since it can pose a fire risk.

How to Replace a Gas Grill Control Valve: Final Thoughts

Your gas grill’s control valve plays an important role in making sure your grilling experience is safe and efficient. If your control valves get stuck or broken, you’ll want to replace them as soon as possible.

By following the steps in this guide, you can successfully replace your gas grill control valve and get back to grilling.

Just remember to make sure your gas supply is off or disconnected prior to replacing the valve, and when in doubt, always check your grill’s user manual for instructions specific to your model.

With the right tools, knowledge, and attention to detail, you can maintain your grill’s functionality and enjoy countless hours of outdoor cooking for years to come.




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