Weber Grills Troubleshooting: Regulator Problems and More • BBQ Host (2024)

The Weber brand might be renowned for quality and durability, but that doesn’t mean that their grills will always work perfectly. With gas grills in particular, there’s always a chance that something could go wrong. This Weber grills troubleshooting guide will help you deal with any problems that might arise.

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Weber Grills Troubleshooting: Common Issues

Before you begin, make sure you have a Phillips head screwdriver and a stiff-bristled brush on hand. We would also recommend investing in a plastic spray bottle for applying the soap solution (see Performing a Leak Test, below).

The Grill Isn’t Heating Up

This complaint is usually caused by issues with the regulator. The regulator is the small segment of pipe that connects the grill to the gas supply. Weber grill regulator problems can cause the burners to produce only a tiny glimmer of flame–or sometimes none at all.

If the issue isn’t with the igniter system or the gas supply, a regulator reset could do the trick. First, turn all the burner control knobs and the tank valve to their “OFF” positions. Take the regulator valve off the gas tank by pulling the metal collar toward the tank, then pulling the valve in the opposite direction.

When you’ve removed the valve, turn each burner knob to “HIGH” and wait for at least one minute, then switch them all off again.

Next, you’ll want to hook the regulator valve back up. Pull the metal collar back toward the tank and insert the tip of the valve directly into the tank. Make sure the valve is secure, then switch the tank valve back on. Attempt to use the grill as you normally would.

Bypass Mode

If the reset procedure doesn’t solve your Weber grill regulator problems, it might be because the grill has gone into bypass mode.

Since 1995, Weber has included a gas detection device inside all of its propane hoses or regulators. The use of this safety feature has been mandated by the federal government to reduce the inherent risks of cooking over a gas flame. Here’s how it works.

You’ll need to light the grill in a specific way to avoid “tripping” the safety device. If you don’t follow the directions to the letter, the device is going to proceed as if you have a gas leak, which will restrict the flow from the tank.

When the regulator is in this bypass mode, the gas flow will be extremely low—around 10 percent of its usual volume, perhaps less. That means that the burners won’t be able to deliver the flames that you’ve come to expect from your Weber grill. In fact, depending on how low the gas flow is, the burners might not ignite at all.

If you suspect that the grill is in bypass mode, you should perform a leak test before doing anything else. You may have already taken this step when you first installed the gas tank, in which case you’ll be familiar with the procedure. If so, feel free to skip ahead to Next Steps, below.

Performing a Leak Test

To start, make a solution that’s about 1 part dish soap and 4 parts water. Use this mixture to wet down the fittings on the regulator. You can apply the solution with a spray bottle, a damp rag, or a regular scrubbing brush.

Slowly turn on the gas, twisting the tank valve counterclockwise. Check the fittings and connections for soap bubbles. If there aren’t any, then you don’t have a leak and the insufficient heat supply is caused by something else. However, if you do see bubbles, then you’ll need to take immediate action.

If you spot the leak at the cylinder, then turn off the gas and disconnect the tank. Return the fuel tank to the retailer who supplied it. If the leak is located at the regulator, turn off the gas and contact Weber’s customer service department. In either case, don’t attempt to operate the grill until you’ve resolved the issue.

Don’t forget to rinse all the fittings and connections after you’ve performed the leak test. The soap and water solution could corrode the metal and reduce the lifespan of your grill.

Next Steps

After you’ve ruled out a gas leak, you can override the bypass mode. These steps will also help you avoid going into bypass later on.

First of all, open the lid of the grill and turn all the knobs to the “OFF” position. If the grill has a side burner, make sure that one is set to “OFF” as well.

Open the tank valve to turn on the gas flow, then wait for a few seconds. You want pressure to build up in the hose so that the safety device will be pushed back into its default position. Once this happens, the grill should be able to operate normally. The waiting period is the most crucial part of the process, so be patient.

Once you’ve waited for 10 to 15 seconds, turn one of the burners to high and press the igniter button. Depending on which model you use, the lighting process may be slightly different; check your user’s manual for instructions if necessary.

Light all the rest of the main burners, setting them all to high. Close the lid and wait about 10 minutes. The grill should be able to hit 500 degrees Fahrenheit during this time.

Be aware that the pressure might take longer to equalize if it’s especially cold outside. In this case, you’ll need to wait a bit longer before lighting the burners.

Other Tips

If the grill still isn’t getting hot, take a look at the control knobs. Are you sure they’ve been set to high?

You can also use a different thermometer to gauge the internal temperature. The lid thermometer might be displaying an inaccurate readout.

It’s also a good idea to check the fuel level in your propane tank and ensure that the regulator is attached securely. If none of these solutions solves the problem, contact Weber’s customer service department.

Burners Won’t Light

When you turn on a burner and press the igniter button but nothing is happening, first make sure that the tank valve is switched on. Then check the gas flow by using a match to light the burner. If this works, then the igniter is at fault.

Check the ignition wires to ensure that they’re properly attached. Then press on the button again. It should click before returning to the outward position. For grills in the Spirit line, make sure the ceramic igniter has been fully inserted into the burner tube igniter channel.

If the ignition system uses a battery, you can check to make sure it’s installed correctly. Replace it with a fresh one if necessary.

Burners Aren’t Lighting All The Way

Let’s say the burners have lit, but the flames are too low when the burner is set to high. In this case, a diminished fuel supply is likely to blame. Check the propane tank or cartridge and refill or replace it as needed.

For full-sized gas grills like the ones in the Spirit, Genesis, or Summit series, you can also check and straighten the gas hose. Insufficient gas flow can disrupt the consistency of the flames.

Similarly, if the flame pattern is uneven, or if the flames don’t run the entire length of the burner tube, you’ll probably need to clean the burner ports. Wait until the grill has had a chance to cool, then refer to the Maintenance segment of your user’s manual for advice on cleaning the ports.

Flames are Bright Yellow or Orange

When the flames are yellow rather than blue, the spider and insect catch screen is probably blocked. Inspect and clean the component as needed.

This issue generally occurs in conjunction with the smell of gas, which is always a sure sign that something is wrong (see below).

Hissing Sound Accompanied by Gas Smell

When you notice a hissing sound and/or the smell of gas, take a look at the rubber seal in the LPG cylinder valve. It’s probably cracked or otherwise damaged. In this case, it will need to be returned to the retailer for a replacement.

Frequent Flare-Ups

When you experience flare-ups, it’s usually because the inside of the grill has gotten too dirty. If there’s excessive grease buildup in the cookbox, the grease won’t be able to flow down into the catch pan. Buildup on the grilling grates can also lead to flare-ups.

Be sure to clean the burners, grilling grates, and cookbox regularly. We would also recommend allowing the grilling grates to preheat for 10 minutes before adding any ingredients.

Grill Won’t Maintain Stable Temps in Cold Weather

When the temperature outside dips below 50 degrees, the propane may be taking too long to transform into vapor. This can restrict the gas flow, which means that the grill won’t be able to hold its heat long enough to cook your ingredients.

Check the outside of the LP tank. Is it coated in frost or ice? If so, it will need to be disconnected and replaced with a new one.

Inside of Lid is Peeling

If the inside of your grill lid looks like it’s peeling, the issue is caused by grease buildup. The burned-on grease has turned to carbon, which is now beginning to flake off. Because the cookbox is made of cast aluminum and is not painted, it won’t actually “peel” on its own. Cleaning the lid will resolve the issue.

Misaligned Cabinet Doors

This is a cosmetic issue that can occur in the Weber Summit S-670 or E-670, or any other grill that has a cabinet-style design. To fix it, check the adjustment pins on the base of each door, then loosen the nuts and adjust the doors as needed. When you’re finished, tighten the nuts again so the doors will remain in place.

Grill Light Won’t Turn On

If the lid of your Weber grill is equipped with lights for evening cookouts, it will only activate when the lid is open. Try pressing the “AWAKE” button once you’ve lifted the lid. Battery replacement might also be in order.

Remember that the light will automatically shut off after 30 minutes if there’s been no grill activity during that time. You can relight it by pressing the “AWAKE” button.

When the light won’t shut off, it’s probably because the lid of the grill is ajar. Make sure to close it completely when you’ve finished grilling.

Final Thoughts

If you clean and maintain your grill as directed, you might not have to worry about many of the issues listed here. Weber grill regulator problems can sometimes throw amateurs for a loop, but as long as you understand what the component is and what it’s for, you should be able to correct the issue in no time.

Best of luck, and happy grilling!