Weber Summit Series Guide

MANIFOLD repLAceMeNt
INstructIONs
NOTE: The grills illustrated or photographed may have slight differences than the model purchased.
THIS PROCEDURE MUST BE PERFORMED BY AN AUTHORIZED
WEBER-STEPHEN PRODUCTS CO. SERVICE TECHNICIAN.
(ANY UNAUTHORIZED REPAIRS WILL VOID WARRANTY PROTECTION).
 DANGER: BEFORE PERFORMING ANY WORK MAKE SURE THE GAS SUPPLY IS TURNED OFF AT THE SOURCE.
FAILURE TO FOLLOW DANGERS, WARNINGS AND CAUTIONS CONTAINED IN THIS INSTRUCTION SHEET MAY CAUSE A
FIRE OR AN EXPLOSION RESULTING IN SERIOUS PERSONAL INJURY OR DEATH AS WELL AS DAMAGE TO PROPERTY.
WARNING: GENUINE WEBER-STEPHEN REPLACEMENT PARTS MUST BE USED FOR ANY REPAIR OR REPLACEMENT.
YOUR ACTIONS, IF YOU FAIL TO FOLLOW THIS PRODUCT WARNING, MAY CAUSE A FIRE, AN EXPLOSION, OR
STRUCTURAL FAILURE RESULTING IN SERIOUS PERSONAL INJURY OR DEATH AS WELL AS DAMAGE TO PROPERTY.
(WILL VOID ALL WARRANTY PROTECTION.)
MANIFOLD
REPLACEMENT
56413 08/06/09
1CONTROL PANEL REMOVAL
TOOLS NEEDED: - PHILLIPS
BEFORE STARTING: Make sure the lid is down and the casters
are locked to prevent the grill from moving.
A) Remove all of the burner control knobs by pulling up.
A B
A - Part# 41788 B - Part# 41787
B) Remove the black phillips head screw and nylon washer on the left and
right side of the control panel.
Part # 42536
Part # 42537

1CONTROL PANEL REMOVAL (cont.)
C) Put your fingers under the front edge of the control panel and lift up
slightly(1).
Move the control panel out from under the fire box end cap control panel
brackets and lift panel up and out from the unit. Set aside so it will not get
scratched.
2FRONT PANEL REMOVAL
A) Remove the stainless steel front panel by lifting the panel up and out of the
fire box end cap locating slots.
3BATTERY CASE REMOVAL
A) Unscrew the battery cap with red button from the battery case. The case
is upside down Remove the spring and battery from the case by pulling in
a downward motion. If the battery does not come out easily, wait until
you remove the battery case from the heat shield and igniter mounting
bracket to remove the spring and battery.
Part# 42053
B) Using an adjustable wrench loosen the nut that holds the battery case to the
heat shield and igniter mounting bracket (1).
1
1
TOOLS NEEDED: - PHILLIPS

3BATTERY CASE REMOVAL (cont.)
C)Hold the battery case and manually finish removing the nut by hand, and
then lift up on the battery case to remove from brackets. Remove the top
positive (+) and bottom negative (–) wires from the case after it is removed.
4IGNITION MODULE REMOVAL
A)Cut and remove the two nylon wire ties from the ignition module (1).
B)Using a phillips screwdriver remove the two mounting screws from the left
and right of the ignition module. This allows the module to swing down freely.
C)The module can be allowed to hang in place with all the wires still attached,
as shown (2).
1
TOOLS NEEDED: - PHILLIPS
2
4IGNITION MODULE REMOVAL (cont.)

5DISCONNECT THE I.R. CONNECTIONS
(Silver D and Gold D only)
A)Using an 8mm open end wrench, loosen nut on thermocouple and unscrew
fitting by hand (1). Once disconnected move thermocouple down and out of
the way. Do not bend the thermocouple capillary (2).
B)Using a 9/16" open end wrench, loosen and remove the ss I.R. Corrugated
gas line from the I.R. valve (3).
6DISCONNECT THE MAIN GAS LINE
A)Using a 7/8" open end wrench, loosen the main ss corrugated gas line from
the manifold (1). I f there is a copper 45° degree washer, inside of the brass
connection on the end of the tube (2), it will be loose and can fall out.
Do not reuse the copper gasket. When reassembled check for leaks.
7MANIFOLD REMOVAL
A)Using a phillips head screwdriver, locate the screws on both sides of the
manifold frame(1) and remove the screws from the frame.
Part #42541
8-32 x ½"
Phil Pan HD Blk
12
3
1
2
TOOLS NEEDED: - PHILLIPS
TOOLS NEEDED: TOOLS NEEDED: - 7/8"
1
- 9/16", 8mm

B)The manifold is now ready to be removed from the burner tubes. Pull the
manifold away from the burner tubes (3). The burner tubes may move with
the manifold as it is removed and dislodge from the mounting slot in the rear
channel. They must be assembled back into the slot before the manifold is
reassembled.
7MANIFOLD REMOVAL (cont.)
8INSTALL NEW MANIFOLD
Please note:The difference between the Original Manifold and the New
Replacement manifold is how the right side mounts into the “C” channel
manifold slide. The left side remains unchanged It is the same for both the
SUMMIT SILVER & GOLD 4 AND 6 BURNER MODELS.
A)The new replacement Manifold comes with it own separate Mounting
Bracket, which fits both the Silver and Gold SUM 28” / 36” New Replacement
Manifolds.
The original manifold has both the right and left side mounting
brackets (1).
The new replacement manifold does not have the right side mounting
bracket (2).
2
1
The new replacement manifold comes with it own separate mounting bracket,
which fits both the Silver and Gold SUM 28” / 36” new Replacement Manifolds.
B) Install bracket onto the right side of the manifold only (3).
3
C).Before reinstalling the manifold make sure that the burner tubes are properly
installed into the mounting slots of the rear channel on the
cookbox (4).
4
3
8INSTALL NEW MANIFOLD (cont.)

8INSTALL NEW MANIFOLD (cont.)
D)Position the new manifold in front of the burner tubes for reassembly.
E)Install manifold paying attention to the position of the right side mounting
bracket. Make sure that the mounting bracket (5) slides over the outside
edge of the C channel (6).
6
5
BEFORE PROCEEDING MAKE SURE THAT THE BURNER TUBES ARE
PROPERLY LINED UP WITH THE VALVES ON THE MANIFOLD.
F)Install mounting hardware. The new mounting bracket comes with a clevis
pin and hair pin cotter. Line up the Mounting bracket hole with the mounting
hole in the “C” Channel Manifold slide (7).
G)insert the clevis pin down through the mounting holes (7) and insert the
cotter pin through the clevis pin mounting hole locking it in place (8).
78
7
G).line up the left side of the manifold with the bracket and reassemble the
mounting screw (9).
9REINSTALL MAIN GAS LINE
A)Using a 7/8" open end wrench, reinstall the main ss corrugated gas line to
the manifold.You must replace the copper 45° degree washer inside of the
brass connection on the end of the tube (1). Do not reuse the old copper
gasket. When reassembled check for leaks (See proper instructions for
leak checks later in this instruction manual).
9
TOOLS NEEDED: - 7/8"
1
8INSTALL NEW MANIFOLD (cont.)

11 CHECK FOR GAS LEAKS
10 REINSTALL I.R. GAS LINE
(Silver D and Gold D only)
A)Using a 9/16" open end wrench, reinstall the ss I.R. Corrugated gas line to
the I.R. valve (1).
B)Reinstall the thermocouple capillary line. Start the threads by hand and
using an 8mm open end wrench tighten connection (2). Do not bend the
thermocouple capillary (3). When reassembled check for 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 open flames will result in a fire or
explosion, which can cause serious bodily injury or death
and damage to property.
C) 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.
D) When leak checking is complete, turn gas supply off at the source and rinse
connections with water.
Check:
A) Gas supply to IR burner valve assembly (1) on models SilverD and
Gold D only.
B) Gas supply to manifold connection (2).
 DANGER: If there is a leak at connection (1 or 2), retighten
the fitting with a wrench and recheck for leaks with soap and
water solution. If a leak persists, turn OFF the gas. DO NOT
OPERATE THE GRILL. Failure to follow dangers, warnings and
cautions contained in this Instruction sheet may cause a fire
or an explosion resulting in serious personal injury or death
as well as damage to property. Contact the Customer Service
Representative in your area using the contact information on
our web site. Log onto www.weber.com®.
C) Valve to manifold connection (3).
D) LP: Regulator connection (4).
E) NG: Hose to quick disconnect gas line connection (5).
 DANGER: If there is a leak at connection (3, 4, or 5), turn
off the gas. DO NOT OPERATE THE GRILL. Failure to follow
dangers, warnings and cautions contained in this Instruction
sheet may cause a fire or an explosion resulting in serious
personal injury or death as well as damage to property. Contact
the Customer Service Representative in your area using the
contact information on our web site.
Log onto www.weber.com®.
When leak checks are complete, turn gas supply OFF at the source and rinse
connections with water.
1
2
NG
LP
Gas Sources:
3
4
5
You will need: a soap and water solution and a rag or brush to apply it.
A) Mix soap and water.
B) Turn on the gas supply at the source.
TOOLS NEEDED: - 9/16", 8mm
1
23

12 REPLACE IGNITION MODULE
A)Make sure that all wires remain connected to the ignition module.
B)Replace ignition module back into mounting position. Using a phillips
screwdriver secure the two mounting screws on the left and right of the
ignition module (1).
C)Replace the two nylon wire ties to the ignition module (2).
13 REPLACE BATTERY CASE
A) Replace battery case to heat shield. Using an adjustable wrench tighten
the nut that holds the battery case to the heat shield and igniter mounting
bracket (1).
B) Replace the Spring and battery back into the battery case. Replace and
screw the battery cap with red button back onto the battery case.
1 4 REPLACE FRONT PANEL
A) Replace the stainless steel front panel. Slide the panel down and back into
the fire box end caps locating slots.
1
2
1
TOOLS NEEDED:

15 REPLACE CONTROL PANEL
A) Slide the back edge of the control panel in and under the fire box end cap
control panel brackets. Push the control panel all the way in and down over
valves.
TOOLS NEEDED: - PHILLIPS
A B
A - Part# 41788 B - Part# 41787
Part # 42536
Part # 42537
B) Replace the black phillips head screw and nylon washer on the left and
right side of the control panel.
A) Replace all of the burner control knobs.