Char Broil Grill Flame Shooting Out [Solved A-Z]

The main reasons behind your Char Broil grill flame shooting out are grease build-up, blocked venturi tubes, tripped regulators, gas leaks, and misaligned burners.

Each of these issues can make the flame escape from places it shouldn’t –  like the front panel or control knobs. But don’t panic. Once you know what’s causing it, fixing it is simple. Let’s go through every reason one by one and get your grill burning safely again.

What Flames Shooting Out Usually Means (Not Just a Flare-Up)

We’ll talk about all the reasons why your Char Broil gas grill is shooting out flames. But before that, you must understand how it’s different from a normal flare-up.

Then, we’ll go through some basic safety checks you should always remember when working with the heaters. Then, we’ll tackle each problem one by one. 

When your Char Broil grill starts shooting flames out the front or near the control knobs, that’s not a normal flare-up. A flare-up is what happens when fat or oil drips onto the burners and catches fire for a few seconds.

It’s short, contained, and happens right under your food. But when you see flames coming out from places like the control panel, sides, or vent holes, that’s a different story altogether.

This kind of flame means the fire isn’t staying where it should. Instead of burning cleanly along the burner ports, it’s sneaking backward through the burner tubes or igniting built-up grease in the lower part of your grill. That’s what I call a “flashback” or “back-burn.”

So, if you’re seeing flames where they shouldn’t be – like out the front or from underneath the control knobs, it’s your grill’s way of yelling for help. It’s not about the grill having too much gas. It’s about poor airflow or trapped grease that’s forcing the fire to escape.

The good news is that once you know this, fixing it isn’t too hard. You just need to figure out what the issue is, and I’ll walk you through exactly how to fix a Char Broil grill flame shooting out in the next sections.

Before you even think about checking what’s wrong, make sure your grill is safe to touch. Turn all the burner knobs off first, then close the propane tank valve tightly to cut off the gas supply completely.

Keep the grill lid open so the leftover heat and gas can escape instead of building up inside. Let everything cool down for a few minutes. Remember that rushing this part can make things worse. It’s good to keep a fire extinguisher nearby whenever you’re grilling, especially when dealing with flame issues.

And remember this one rule that could save you a lot of trouble: never pour water on a grease fire. It doesn’t put it out – it spreads it. If the fire flares up again, close the lid, kill the gas, and wait until it burns out safely. With all that in mind, now you’re ready to diagnose the individual issues and solve them.

Char Broil Grill Flame Shooting Out [Solved A-Z]

Here are the main reasons why your Char Broil grill shoots out flame, along with the fixes:

1. Grease Build-Ups

This is the most common reason behind this issue. When there’s a grease build-up, you’ll see sudden flames shooting up under the grates, around the heat tents, or maybe even escaping from the drip-tray area.

Instead of a short flare when you flip a burger, this is a bigger fire trail caused by pooled grease catching light. So, how can you check this and be sure that this is the issue?

Lift the cooking grates and remove the heat tents (flame shields) if your model allows you to do so. Inspect the drip-tray or grease pan – look for puddles of fat, thick sticky residue, or burnt-on deposits. These are prime fuel for a runaway flame.

Solution:

If the inspection reveals that this could be the issue, you can follow these steps to fix it:

1. If food is still cooking and you see heavy flames, move it to a cooler zone away from the fire.
2. Kill the burners that are causing the flare-up (turn them off), open the lid to vent excess heat safely.
3. Once things calm down, with the grill off and cool, remove grates and heat tents.
4. Scrape out the grease tray, brush off burnt-on fat from the heat tents, and under the grates. Then fire the grill on high (lid open) to “burn off” remaining residue as instructed by the manufacturer. 
5. Reassemble and start fresh.

To prevent gas grill flame flare-ups in the future, make cleaning part of your grilling routine. After every cook, scrape the grates to remove leftover food and empty the drip tray before it overflows.

Once a month – or more often if you frequently grill fatty foods – take a bit of time to do a deeper clean of the heat tents and grease pan. Following these steps keeps your grill in top shape and ensures safer, more consistent cooking.

2. Venturi Or Tube Blockage

One of the most common reasons behind it is spider webs. When facing this problem, you’ll notice flames coming out where they shouldn’t. It’ll often be near the control knobs or front panel of your grill – classic signs of grill burner port blockage.

Maybe you’ll hear a sudden whoosh when you open the lid. You might also see uneven flames across burners, or a burner that lights weakly while another goes full tilt. That’s a classic sign that the normal path of gas and air to the burner is being disrupted.

To be sure if this is the problem, start by shutting off the propane tank valve and turning off all the burner knobs. Keep the lid open and let the grill cool down completely before you touch anything.

Once it’s cool, remove the cooking grates and the burner flame shields so you can clearly see the burner tube assembly underneath. Take a close look at the venturi tubes, which are the narrow metal tubes that connect the gas valve or orifice to the burners.

If you notice spider webs, insect nests, small bits of debris, or any kind of blockage inside those tubes, that’s most likely the reason flames are shooting out the front or behaving oddly.

While you’re at it, inspect the burner positioning and the carry-over tubes to make sure everything is properly aligned and hasn’t shifted out of place, since misalignment can also cause the flame to divert.

Solution:

If you’ve found spider webs or debris in the venturi tubes, it’s time to clear them out before firing up the grill again. Start by using a long, narrow brush- often called a venturi tube cleaning brush for this job. You can even use a pipe cleaner to gently remove any obstructions inside the tubes.

Make sure you remove all insect material or debris you find. After cleaning, reinstall the burners and double-check that they’re seated correctly. On top of that, double-check that they’re properly aligned with the tubes and valve orifices, and that the carry-over flame path is intact.

Once everything is in place, slowly open the propane valve, light the grill with the lid open, and watch how the flames behave. They should burn evenly and only where they’re supposed to.

If you still notice flames shooting out the front or burning near the knobs, there may be deeper issues, such as damaged venturi tubes or mismatched replacement parts, in which case it’s best to have it replaced.

To prevent this issue from happening again, make cleaning your venturi and air tubes a regular part of your seasonal grill maintenance. Especially if the grill hasn’t been used for a while.

If your model allows, use insect screens or protective caps on the venturi openings to keep spiders and insects out, and always cover your grill when it’s not in use. It’s also important to inspect the burner assembly regularly to ensure the tubes are properly aligned and free from rust or damage.

At the end of each grilling season, look for any discoloration or burn marks near the control panel, as these can be signs of a previous flashback event and may mean it’s time to inspect or replace the affected parts.

3. Tripped or Weak Regulator

When you notice your Char Broil grill suddenly shooting out flames one second, weak and sputtering the next – there’s a good chance the regulator or excess-flow valve is to blame. This could also cause your Char Broil grill flame too low or irregular.

The regulator is that small, round device connected to the propane tank. It controls how much gas flows from the tank to the burners. But when it gets tripped or stuck, it either sends too little gas or lets gas rush too fast, which can cause flare-ups or even flames bursting out where they shouldn’t.

This happens more often than you might think. Especially if the tank valve is opened too quickly or if there is a small leak or pressure surge. So, opening the tank valve too fast can trigger the excess flow device, restricting gas flow and causing abnormal flame behavior.

Here’s how to know if this is your problem:

• You’re getting either very weak flames or sudden, large bursts of fire.
• You recently swapped or refilled your propane tank.
• You opened the tank valve too quickly.
• You hear faint hissing or irregular pulsing from the regulator.

If any of these sound familiar, it’s almost certainly the regulator or the excess-flow safety valve acting up.

Solution:

The first thing you have to do is try to reset the Char Broil gas grill regulator. This is a simple process and works for most Char-Broil gas grills. Follow these steps to do it:

1. Turn off the propane tank valve completely – twist it clockwise until snug.
2. Turn off all burner knobs on your grill.
3. Disconnect the regulator hose from the propane tank.
4. Wait about one minute to allow the regulator to reset internally.
5. Reconnect the regulator securely to the tank.
6. Now, open the propane valve slowly – do it about a quarter turn at a time to avoid tripping the excess-flow device again.
7. Light your grill with the lid open, and check if the flames are stable and blue.

If the flames return to normal, your regulator was tripped earlier. You’re good to go now. If the problem continues, your regulator may be faulty or worn out. Regulators don’t last forever – Char-Broil recommends replacing them every few years or whenever you see inconsistent flame patterns.

How To Replace Char Broil Gas Regulator?

If you’ve done the reset and the grill still acts up, it’s time to replace it. You can find OEM Char-Broil replacement regulators on the Char-Broil official parts store or hardware sites like Lowe’s and Home Depot. Follow these simple steps to replace the regulator on your grill:

1. Turn off everything and disconnect the tank.
2. Use an adjustable wrench to unscrew the old regulator.
3. Attach the new one by hand-tightening it clockwise – no need for pliers.
4. Once connected, apply a soapy water solution around the connections and open the tank valve slightly.
5. If you see bubbles forming, tighten the fittings until no bubbles appear.
6. Light the grill again and observe.

If you see steady blue flames, that means the job was successful. If you’re still seeing flame related issues, then the reason could be something else.

Tip: Never use Teflon tape on the tank side connection; regulators are designed to seal with rubber gaskets already in place. If you need more detailed instructions on replacing the Char Broil gas regulator, I have a dedicated guide on it. Check it out.

To prevent the gas grill from tripping in the future, you can follow these practices:

• Always open the tank valve slowly, never fast.
• Avoid storing the grill with the valve left open.
• Keep the regulator dry – moisture or rain can corrode the spring inside.
• Replace the regulator every few years or when you notice constant flame inconsistencies.

4. Gas Leak Issue

If you’ve already checked your propane tank and regulator, but the flames are still acting strange, the next culprit to suspect is a gas leak. A leaking hose or loose fitting can cause your gas grill to shoot flames near the control knobs.

Leaks aren’t just about wasted propane. Even a tiny one can let gas escape around the hose or fittings, which can suddenly ignite and cause flames to shoot out near the control knobs or along the hose.

You might notice a faint propane smell, a hissing sound, or flames flaring up close to the regulator area. That’s your grill’s way of telling you something’s not sealed right. The safest and easiest way to confirm a leak is the good old soapy water test. Here’s how to do it:

1. Turn off the grill completely – make sure all burner knobs are off.
2. Close the tank valve tightly by turning it clockwise. Mix a few drops of dish soap with water in a bowl or spray bottle.
3. Brush or spray the solution generously over all gas connections: the regulator-to-tank connection, the hose length, and the hose-to-grill connection.
4. Slowly reopen the propane valve just a little – do not light the grill.
5. Watch for bubbles forming in the soapy water.

If you see bubbles, that’s where gas is leaking out. Turn off the valve immediately and don’t use the grill until it’s fixed.

Solution:

Once you’ve found the source of the leak, you need to fix it. Here’s what to do for each of the areas:

If it’s at a joint or fitting:

Try tightening the connection gently with a wrench. Don’t overtighten – just snug enough that it seals.

If it’s at the hose itself:

Replace the hose. Char-Broil sells regulator-and-hose kits made specifically for their grills, and they’re usually a direct fit.

If it’s at the tank connection:

Check for dirt, rust, or damage around the tank valve. Clean the connection gently and ensure the rubber seal is intact.

After every repair or replacement, repeat the soapy-water test to confirm it’s completely sealed. Only then should you light the grill again. Follow these safety tips to make sure you’re protected at all times:

• Never test for leaks with an open flame.
• Always test after switching propane tanks or replacing any gas component.
• If you ever smell strong gas while cooking, shut off the tank and step back immediately. Let it air out before inspecting.
• Char Broil recommends checking for leaks before every grilling season or any time you reconnect the tank.

Once your grill is leak-free, you’ll instantly notice the difference. There’ll be no random bursts of flame, no weak burners, and definitely no scary flare near the control panel. This simple 5-minute check can literally save your grill.

5. Misaligned Or Damaged Burners

If you’ve ruled out the previous issues but the problem still prevails, the next likely cause is a misaligned or damaged burner. It could also just be the heat shield that’s bent due to excessive heat. But since it’s a part of the burner, let’s look at them together.

Your burners are what distribute the gas evenly across the cooking area. If even one is out of place, clogged, or corroded, gas can escape in the wrong direction and ignite outside the burner ports. That can lead to those sudden flames bursting from the sides or front panel.

Follow these steps to check if the issue is with your burner:

1. Turn everything off and let the grill cool.
2. Open the lid and remove your cooking grates and the metal heat tents.
3. Inspect the burners underneath. Look for:

• Burners that appear loose or crooked.
• Rust holes, cracks, or burnt spots.
• Blocked or unevenly lit burner ports.
• Heat shields (metal covers) that are greasy, warped, or sitting unevenly.

If the burners are even slightly out of place, the gas flow won’t match up with the control valves properly. That’s when the flame travels somewhere it shouldn’t – like near the control knobs or the grill body edges.

Solution:

The first thing you have to do in this scenario is to try and clean the burner. Follow these steps to do it:

Step 1 – Remove and Inspect the Burners

Pull out the cotter pins or clips holding the burners in place. Slide them backward off the valve orifices and lift them out. If the carry-over tubes between burners are bent, remove and clean them too.

Step 2 – Clean Burner Ports

Use a grill brush or small wire to clear the tiny holes (ports) along each burner. Make sure the holes aren’t rusted shut or blocked with debris.

Step 3 – Realign Burners Properly

Slide each burner back onto the gas valve orifice until snug. Make sure the carry-over tubes line up straight across burners – this ensures flames can travel smoothly when you light multiple burners.

Step 4 – Check the Heat Shields

If your heat shields are coated with thick grease or warped from heat, they can redirect the flame sideways. Clean or replace them as needed.

Step 5 – Test Safely

Reassemble everything, open the propane valve slowly, and light the grill with the lid open. The flames should burn steadily and evenly across all burners. No flare should come from the sides or the control panel.

If you still see erratic flames, one of your burners may be too corroded to function properly. In that case, replacement is the only fix.

How To Replace Char Broil Grill Burner?

These are the simple steps to replace the burner in a Char Broil grill:

1. Disconnect the propane tank and remove grates and flame tamers.
2. Remove cotter pins or screws holding the burners.
3. Slide burners out from the valve openings.
4. Compare new burners to old ones for size and fit.
5. Insert the new burners, reattach the pins, and align the carry-over tubes.
6. Reassemble, perform a soapy-water leak test, and light the grill.

Now, this is most likely too short for you. But I’ve explained in detail how to replace the burner in another guide. Check it out for detailed instructions.

Once your burners are aligned and clean, you’ll immediately notice smoother ignition and even heat distribution.  No more sudden bursts of fire or flames escaping from odd places.

6. Wind & Airflow Problems

If your Char-Broil grill suddenly starts throwing flames out of the front or sides on a windy day, don’t panic – this might not be a “grill problem” at all. It could simply be the wind messing with the airflow.

When strong wind hits your grill at the wrong angle, it can blow the flames off the burners or even push them backward through the venturi tubes. That’s when you see flames sneaking out around the control knobs or vent holes.

This doesn’t mean your grill is unsafe – it just means the airflow balance has been disturbed. The burners need a steady mix of gas and oxygen. Too much wind, and the ratio goes off, causing unstable flames or mini flashbacks.

You can easily confirm if the wind is the culprit:

• If the grill only acts up on windy days or when you reposition it outdoors, it’s an airflow issue.
• Flames may appear uneven, flickering, or coming out of the control panel when gusts hit.
• You might even hear a faint popping or “whoosh” sound as the flame gets pushed around.

If the grill works perfectly fine when the air is still, you’ve found your answer – it’s the wind.

Solution:

You need to manage the airflow to fix this issue. Here’s how to stop the wind from interfering with your grill:

1. Reposition The Grill

Move it so that the wind blows across the grill, not directly into the back or front vents. The back is especially sensitive because that’s where the venturi tubes pull in air.

2. Create A Windbreak

If you live in a breezy area, use a wall or sturdy barrier nearby to block the direct wind. Make sure it’s heat-resistant and not flammable – never use fabric or plastic.

3. Keep The Lid Open When Lighting

Lighting the grill with the lid closed traps gas inside, and if the wind pushes flames back, it can cause a quick boom flash. Always light with the lid open.

4. Check the Air Shutters (Venturi Openings)

If the grill is used in a dusty or sandy area, debris can block the small venturi openings, reducing air intake. Clean them gently with a brush or compressed air.

5. Avoid Using the Grill In Strong Gusts

If winds exceed 15–20 mph, it’s best to wait. No amount of repositioning will fix flames being blown out entirely.

There are some things you can do to make sure that the weather has minimal impact on how your cooks go. Keep your grill in a semi-sheltered spot, such as near a brick wall or a corner that helps block direct gusts of wind.

Never grill under a flammable awning or in an enclosed patio, since proper airflow is still crucial for safety. Also, always make sure your grill is level and stable, especially if you’re using it on a balcony or deck.

FAQs:

Conclusion:

Now you know exactly what causes a Char-Broil grill flame shooting out and how to stop it for good. Most of the time, it’s just grease buildup, a blocked burner, or a tripped regulator—nothing too serious.

And if you ever face the opposite problem—weak or uneven heat —I’ve also written a full guide to fixing a low flame on Char-Broil grills that walks you through every easy solution, step by step. Check it out if you’ve ever faced that issue and want the solution.