Burner G511-2900-W1

Replaced the burners that were rusted out

Took out all grates and pans and used a chisel to hammer off the rusted screws to remove the burners and the pop rivets on igniters that still worked had rusted off the so I drilled out the rivets.
Turned grill upside down, and lined up the burner jets after cleaning that had failed and used Diamond tipped dive bits slowly drilling thru the hard metal brackets and used stainless steel screw to reattach the burner jets carefully lining up with the failed spot welds .
Put new burner strikers that came with holes for screwing down and replaced the cover under the burners in the propane tank lower part of grill two screws.

Turned grill back up like normal and then carefully lined up the burners on the now firmly attached burners.
Mounted the igniters so there was a 1/8 inch gap and the tip was in front of one of the new burners.
Hooked up propane , put battery in and turn on burners. The left two lighted fast and nice blue flame. Had to take a small drill bit by hand and cleaned the now solid mounted right jet after removing the burner and turned gas on and stuff blew out of orfice gas jet.
Put new burner back on, had to use larger screws , due to the holes being widen when I chiseled them out. Put in pans and realized the two front bottom Tabs had broken off, so I used two thread bolts and nuts to hole the pan the proper height. Put grates back on and turned each burnèr on right to left and like new the all fired right up.
I had replaced the pans in 2015 as grill sat out in weather and was used all winter and summer long. Note do not unscrew burner jets to clean as the manual states. I did one and the casted port broke on each side by the screw holes and did not see them available. I used a clip to cover the broken sides and secured that gas jet.
I bought this grill in 2009 at Home Depot and ereplacement was the only place I could find the burners with 10 in stock and bought 6 strickers so if burners fail again now under a covered roof over the deck right outside my front door. So for 3 new burners and 3 new strikers that totaled 70 dollars and 3 hours of fixing failed Char Broil spot welds I have a 700 dollar grill in perfect shape that design is far superior to the new design that has tent like covers to deflect grease and replacement burners next to display.
This grill was designed to last by having the pans keep all grease and droppings from burners. I honestly could of used the old burners, but they were rusty and the flame was yellow because mfg failed to tack weld the burner plates and even wth one side of each burner broken it’s now fixed better and the infrared heating design will bring up the grill to 400 degrees jn less than 4 minutes when it’s 3 below and wind blowing 30 miles a hour, I can open my door start grill Right up, and have beautiful seared steaks in less than nine minutes. Also I had to replace the regulator learned the hard way taking a cylinder that was almost as heavy and the gage did not read because the reg had failed.
Bottom line remove burners and if still attached spray WD 40 into jets and no j hook as manual suggests will work. If jets are secure and lined up with burners one might get by with cleaning by hand with a small drill bit by hand. But we’ll worth the money to replace the burners. You save yourself a bunch of money and a great design.
Love epartsreplacement and so glad by chance I heard got the link to them recommended by a you tube video guy repairing a old grill like mine. Parts came quickly delivered to front door. If I can fix that grill anyone can.

Disassembled and reassembled, pretty simple. Burner screws had rusted to the point I had to drill out the screws, by far the hardest part.

Removed the old burners and installed the new burners.

Removed pans washed grill and around burner screws scrapped rust and charcoal away. Used spray from Ace Hardware one type to clean interior one for exterior and then waxed.
Used Phillips screw driver got 4 of 12 screws out of burners. Rest of screws needed drilled out. After bits all broke used hammer and chisel to remove last 2 screws. Went to Hardware store and got larger screws. Installed 3 burners, installed 2 new pans. Grease cleaned grill plates turned to 500 degrees forgot to shut off cleaned grill great. Electric starter works still. Had to mark handles cleaner remover labels for nobs that were always confusing with permanent black marker ! Cooked perfect bacon wrapped fillets seared then cooked to perfection. Then brats. Still have no figured out how to use rotisserie and how it mounts.