STEP 1

Remove the Cooking Grates and Flavorizer?? Bars

Your Weber Gas Barbecue must be OFF and cool.

STEP 2

Remove the Control Panel and burner control knobs

Be sure gas is turned off at source.

Remove control panel and burner control knobs

You will need: Phillips screwdriver.

1)Remove control knobs.

2)Remove screws through slots in trim with a Phillips screwdriver.

3)Pull up igniter button until it sticks in the up position and remove control panel from grill.

*If you have a different style grill, put your fingers under the edge of the control panel at the control panel push- in buttons and pull toward you.

STEP 3

Remove the Manifold and Valve Assembly

Unhook the manifold bracket(1) and unscrew the two nuts(2) that hold the manifold to the cooking box. Pull the manifold assembly out of the burners and carefully set it down.

Manifold Valve Assembly

Frame Brace

5)Slide the burner assembly out from under the guide screw and washer(1) in the corners of the cooking box.

Do not loosen screws. The screws are only guides.

(1)

6)Lift and twist the burner assembly slightly, to separate the Crossover?? tube(1) from the burners. Remove the burners from the cooking box(2).

Note: The new burner tubes have an insect screen. The old plastic insect screens are no longer needed.

Old New

1)Slide new burner tubes back through openings in cookbox.

2)Insert Crossover?? tube into the opening at the end of outside burners (a).

If you have a 3rd burner slide the notched end into the bracket on the Crossover?? tube (b) Note:The single row of gas portholes should be facing up.

3)Slide the burner assembly back under the guide screws and washers (b) at the corners of the cooking box.

Do not tighten screws. The screws are only guides.

STEP 5

Reinstall the Manifold and Valve Assembly and the

Control Panel.

Follow steps 1 through 3 in reverse order.

STEP 6

Check for gas leaks.

 DANGER

Do not use an open flame to check for gas leaks. Be sure there are no sparks or open flames in the area while you check for leaks. Sparks or flames will result in a fire or explosion which can cause serious bodily injury or death, and damage to property.

1)Mix soap and water.

2)Turn on the gas supply.

3)Check for leaks by wetting the fitting with the soap and water solution and watching for bubbles. If bubbles form, or if a bubble grows, there is a leak.

If there is a leak, turn off the gas and tighten the fitting. Turn the gas back on and recheck with the soap and water solution.

LP Grills Check:

1)Hose-to-manifold connection.

2)Regulator-to-Cylinder connection.

 WARNING: If there is a leak at connection (1), retighten the fitting with a wrench and recheck for leaks with soap and water solution.

If a leak persists after retightening the fitting, turn OFF the gas. DO NOT OPERATE THE GRILL. Contact Customer Service using the contact information sheet provided with your manual(1-800-446-1071).

Check:

3)Valves-to-manifold connections.

4)The hose-to-regulator connection.

 WARNING: If there is a leak at connections (2), (3) or (4), turn OFF the gas. DO NOT OPERATE THE GRILL. Contact Customer Service using the contact information sheet provided with your manual(1-800-446- 1071).

When leak checks are complete, turn gas supply OFF at the source and rinse connections with water.

If leak does not stop, contact Customer Service using the contact information sheet provided with your manual(1-800- 446-1071). Do not use the barbecue.

5)When leak checking is complete, turn gas supply OFF at the source and rinse connections with water.

(1)

(2)

(3)

(4)

*The grill illustrated may have slight differences from the model purchased

Natural Gas Grills Check:

Check:

1)Hose to manifold connection.

 WARNING: If there is a leak a connection(1), retighten the fitting with a wrench and recheck for leaks with soap and water solution.

If a leak persists after retightening the fitting, turn OFF the gas. DO NOT OPERATE THE GRILL. Contact Customer Service using the contact information sheet provided with your manual(1-800-446-1071).

2)Valves to manifold connection

3)Hose to quick disconnect connection

 WARNING: If there is a leak at connections(2) or(3) turn OFF the gas. DO NOT OPERATE THE GRILL. Contact Customer Service using the contact information sheet provided with your manual(1-800-446- 1071).

When leak checks are complete, turn gas supply OFF at the source and rinse connections with water.

(1)

(2)

(3)

*The grill illustrated may have slight differences from the model purchased