- 1). Turn your grill on high for 15 minutes to burn off some of the residue. Remove any cast iron grates before turning the grill on. Turn the grill off and let it cool completely. Shut off your gas supply source
- 2). Lay a tarp under your grill. Use a tarp that is large enough to hold your grill and allow you to spread your parts out onto it.
- 3). Soak your grates in hot soapy water and degreaser for at least one hour if they are not rusty. Scrub the grates after one hour of soaking with a steel wool pad. Soak the grates again if everything does not come off while scrubbing it. Repeat as necessary.
- 4). Replace your grates if they have broken welds or rust that cannot be removed. Search for missing porcelain, on porcelain grills, and replace if the porcelain is chipped or badly deteriorated.
- 5). Remove the lava grate and lava rock. Replace your lava rock with rock that will not fall through the grate. Set the new grate and rock aside.
- 6). Check under your grill for clips that hold the burner assembly in place. Remove these clips if your grill has any. Pull the burner assembly out of the grill gently and inspect it. Look at the gas holes to see if they are still only uniform holes or if they have burned out.
- 7). Replace the assembly if any of the holes have become enlarged or are burned out. Review the seams to ensure they are still intact. If not intact, replace the assembly. Remove any rust or deposits with a wire brush if your burner is still in good shape.
- 8). Clean the venture tubes with a flexible spider brush if you keep your old burner assembly. Set the assembly aside.
- 9). Push your knobs in and let them go to see if they spring back quickly. Remove the knobs and spray WD40 onto the valve stems. Reinstall the knobs and move them around a few times so the WD40 is spread around. Replace any damaged or broken knobs before reinstalling them.
- 10
Remove the hose from the valve and clean out the orifice with a toothpick. Replace the hose. - 11
Mix some soapy water at 50 percent soap and 50 percent water and spread it on the valve and hose to check for leaks. Tighten the hose using two wrenches and check it again. If there are still leaks, replace the hose and test it again. - 12
Cover the ignitor wires and valve orifice with aluminum foil. Scrape the inside of the grill. Remove all the debris from the inside of the grill that can be scraped off. Vacuum up the debris. - 13
Prepare hot soapy water and scrub the inside of the grill, both the top and bottom, with a scouring sponge or steel wool pad. Remove all dirt, debris and grease. Rinse and dry the grill. - 14
Clean the window with glass cleaner on the inside and outside. Clean the inside of the lid with stainless steel cleaner if your grill is stainless steel. Buff the steel with a clean cloth with the grain. Remove the aluminum foil over the ignitor wires and valve orifice. - 15
Test your ignitor. Tighten the connections if it does not work and test the ignitor again. Look over the wires to identify any corrosion or cracks. If the wires are corroded, there are cracks in the housing or the ignitor still does not work, replace the ignitor. - 16
Clean the grease holes with a wire brush and hot soapy water and degreaser. Remove the grease catch and clean it thoroughly. - 17
Reinstall the burner assembly and the clips. - 18
Place the lava grate down and distribute the lava rock evenly throughout the grill and eliminate as much space between the rocks as possible to prevent grease from dripping through the grate. Reinstall the cooking grates or install the new grates. - 19
Reconnect the gas to the grill and open the gas line. Prepare a soapy solution with 50 percent soap and 50 percent water and rub it on the hose connections between the gas and the hose and look for bubbles to identify leaks. Tighten the hose to eliminate any leaks and test the hose again. Replace the hose if you continue to see leaks. - 20
Clean the outside of the grill with hot soapy water and degreaser. Use a scouring pad to scrub out stains, but do not be too harsh or you may scratch the finish. Repaint your grill using heat resistant paint if you choose. Wash it with the grain with stainless steel cleaner if your grill is stainless steel.
Source...