How to Replace Weber Grill Burner Tubes and Clean Up the Grill

If the burner tubes in your Weber grill are rusted or worn out, replacing them can bring the grill back to life. This repair also gives you a good chance to clean the inside of the grill, inspect the flavorizer bars, and check the igniter while everything is already apart.

In this video, I replace the burner tubes on a Weber Spirit grill, clean the grill with a power washer and foam cannon, replace a discharged igniter battery, and put everything back together.

Watch the Video #

Quick Summary #

To replace the Weber grill burner tubes, open the grill, remove the grates and flavorizer bars, disconnect the propane tank, remove the front control panel, detach the igniter, unscrew the old burner tubes, and pull them out carefully. After that, you can clean the grill, install the new burner tubes, reconnect the igniter and front panel, replace the igniter battery if needed, and put the flavorizer bars and grates back in place.

Opening the Weber grill before replacing the burner tubes

Parts and Materials #

The video description includes these replacement parts:

For the optional cleanup, I used a power washer and foam cannon while the grill was disassembled.

Remove the Grates and Disconnect the Propane Tank #

Start by opening the grill and removing the grill grates. This clears the top of the grill so you can reach the flavorizer bars and burner area.

Removing the grill grates from the Weber grill

Next, detach the propane gas tank before working on the burner system.

Disconnecting the propane tank before the Weber grill repair

With the grates out, remove the old flavorizer bars. In this grill, the old bars were in rough condition, so removing them also made it easier to inspect what else needed attention.

Rusted Weber flavorizer bars removed from the grill

Remove the Front Control Panel #

To reach the burner tubes, remove the front control panel. Start by pulling the control knobs straight off one by one. Pull gently so you do not damage the knobs.

Removing the control knobs from the Weber grill

After the knobs are off, remove the screws holding the front panel. On this grill, there are three screws on the front.

Removing the front control panel screws from the Weber grill

There are also two screws underneath securing the panel.

Removing the underneath screws that secure the Weber grill control panel

Once the screws are removed, take off the front panel carefully.

Weber grill control panel removed during burner tube replacement

Before setting the panel aside, detach the wires from the igniter button.

Detaching the igniter wires from the Weber grill control panel

Remove the Igniter Button #

Now remove the igniter button from the panel. I was able to push it out by hand, but if it does not come out easily, a flat screwdriver can help release it.

Remove the Old Burner Tubes #

With the front panel and igniter out of the way, the burner tubes are accessible. Unscrew the old burner tubes from the grill.

Unscrewing the old Weber grill burner tubes

After the screws are removed, gently pull the old burner tubes out of the grill.

Removing the old burner tubes from the Weber grill

Clean the Grill While It Is Apart #

This cleanup step is optional, but it is much easier to wash the grill while the grates, flavorizer bars, front panel, and burner tubes are removed.

I used a power washer and foam cannon to put foam on the grill.

Applying foam to the Weber grill during cleanup

I also power washed the grill grates before reassembly.

Install the New Burner Tubes #

Once the grill is cleaned up, insert the new burner tubes back into the grill.

After the burner tubes are in place, reconnect the gas tank.

Reinstall the Igniter and Front Panel #

Put the igniter button back into the control panel.

This is also a good time to replace the igniter battery if it is discharged. Mine was dead, so I replaced it with a new one before finishing the assembly.

Replacing the Weber grill igniter battery

Then reinstall the front panel, reconnect the igniter wires, tighten the screws, and push the control knobs back on.

Reinstall the Flavorizer Bars and Finish Assembly #

Put the flavorizer bars back into the grill.

Reinstalling the Weber grill flavorizer bars

After the flavorizer bars are back in place, reinstall the grill grates. At this point, the burner tube replacement and cleanup are complete.

Weber grill reassembled after burner tube replacement

Final Thoughts #

Replacing Weber grill burner tubes is a manageable DIY repair if you take the grill apart in order and keep track of the panel screws, igniter wires, and burner tube hardware. Since the grill is already opened up, it is also a good opportunity to clean the inside, wash the grates, inspect the flavorizer bars, and replace the igniter battery if needed.

After the new burner tubes were installed and the grill was cleaned, the grill looked almost like new again.