How to Set Up and Season Your New Outdoor Grill Before the First Cook

Lay out all parts and hardware on a clean surface and check them against the parts list in the manual. Missing or damaged parts are far easier to address before assembly than after. Most manufacturers have a straightforward parts replacement process. Contact the manufacturer or the retailer where you purchased before proceeding if anything is missing or damaged.

Gather the tools you will need before starting. Most grill assemblies require a Phillips head screwdriver and an adjustable wrench or socket set. Some require a rubber mallet for pressing components together. Having everything at hand before starting makes the process significantly smoother.

Assemble the grill on a grass lawn or place cardboard under it during assembly. Concrete and patio stone surfaces scratch and dent exterior panels and cooking components during assembly. Working on a soft surface protects the finish and makes it easier to position and reposition components without damage.

Finger-tighten all bolts and screws throughout the assembly process and do a final tightening pass only when all components are fully in place and aligned correctly. Fully tightening components as you go makes it difficult to adjust alignment later and can cause components to sit off-square, which affects both appearance and function.

Before moving the assembled grill to its final position, check that all structural connections are tight, all shelves and side tables are properly secured, all wheels are locked, and all burner components are seated correctly. It is significantly easier to adjust components before the grill is positioned against a wall or fence than after.

Ensure the propane tank is full or has sufficient fuel for the initial burn-in. A standard 20-pound propane tank provides approximately 20 to 25 hours of cooking time at medium heat. Connect the regulator to the tank valve by threading it clockwise until it is hand tight. Do not use a wrench to tighten the regulator connection. Hand tight is correct. Over-tightening can damage the connection.

Before opening the tank valve, ensure all burner knobs on the grill are in the off position. Open the tank valve slowly and fully by turning it counterclockwise. A fast opening of the valve can trigger the safety bypass in the regulator, which limits gas flow and will make the grill difficult to light and slow to heat.

Before lighting the grill for the first time, test all gas connections for leaks. Mix dish soap and water in equal parts and apply the solution generously to every connection point along the gas line, including the regulator-to-tank connection, the regulator-to-grill connection, and every burner valve connection you can access. Turn the tank valve on slowly with all burner knobs off.

Watch each connection for bubbles. Bubbles indicate a gas leak at that point. If you observe bubbles at any connection, turn off the tank valve immediately, disconnect the regulator, and inspect the connection for damage or debris. Do not attempt to light the grill until all connections are confirmed leak-free.

Natural gas grill connections should be made by a licensed gas technician if you have any uncertainty about the process. The connection involves attaching the grill's flexible gas connector to the dedicated outdoor gas supply line using a quick-connect fitting or threaded connection depending on your installation.

Once connected, test all connections for leaks using the same soapy water method described for propane connections. Any connection showing bubbles requires attention before the grill is used. Turn off the gas supply at the shutoff valve and consult a licensed technician if a leak is identified.

Cast iron grates benefit most from thorough seasoning and require it most urgently. Unseasoned cast iron will rust quickly when exposed to moisture, including moisture from food during cooking.

Before seasoning, wash the grates with warm soapy water to remove any manufacturing oils or residue. Rinse thoroughly and dry completely. Moisture left on the grates will cause surface rust to develop before the seasoning is complete.

Apply a thin, even coat of a high-smoke-point cooking oil to all surfaces of the grates, including the underside. Flaxseed oil, vegetable oil, and canola oil all work well. Avoid olive oil, which has a lower smoke point and will produce excessive smoke during the burn-in process. Use a cloth or paper towel to apply the oil and wipe off any excess. The coat should be thin enough that the grates do not appear wet.

Place the oiled grates in the grill and heat to medium-high for 30 to 45 minutes. The oil will polymerize, bonding to the cast iron surface and creating a protective layer. Allow the grates to cool completely and repeat the process two to three times before the first cook for optimal seasoning.

Stainless steel grates do not require the intensive seasoning that cast iron does, but benefit from a light oil coating before the first cook. After the burn-in described in the next step, brush or wipe the grates lightly with a high-smoke-point oil while they are still warm. This reduces initial sticking and improves cooking performance.

Re-oil stainless steel grates before each cook as part of your regular pre-cook routine. A clean, lightly oiled stainless steel grate performs significantly better than a dry one.

Porcelain-coated grates should not be seasoned with oil in the same way as cast iron. The porcelain coating provides its own non-stick surface and does not bond with oil the way bare metal does. Clean porcelain-coated grates with a soft brush only. Avoid metal scrapers and steel wool, which will chip the porcelain coating and expose the underlying metal to rust.

Open the lid before lighting. This is a safety step that should be followed every time you light the grill, not only during the burn-in. An open lid prevents gas accumulation in the cooking chamber during the lighting process.

Light one burner at a time, starting with the burner closest to the ignition point, and verify each burner lights successfully before proceeding to the next. All burners should produce a steady, even blue flame with small yellow tips. A fully yellow or orange flame indicates an air-to-fuel mixture issue that should be addressed before cooking.

Once all burners are lit, close the lid and turn all burners to high. Allow the grill to run at maximum temperature for 20 to 30 minutes. During this time you will likely see smoke coming from the grill as manufacturing residue burns off. This is normal and will diminish as the burn-in progresses.

After 30 minutes at high heat, open the lid and inspect the cooking surfaces. The grates should be hot, the flame tamers should be clean and glowing, and the interior of the lid should have started to develop a darker patina from the heat. This is normal and desirable.

Observe the flame pattern on each burner. The flame should be consistent along the length of the burner tube with no cold spots. A cold spot, visible as a section of burner with no flame or a much lower flame than adjacent sections, indicates a blocked burner port. Turn the grill off, allow it to cool, and clear the blocked port with a thin wire before proceeding.

Listen for any unusual sounds, including hissing that might indicate a gas leak or excessive popping that might indicate ignition issues. A clean-burning gas grill should run relatively quietly.

Check the temperature gauge on the lid. A four-burner gas grill on high should reach between 500 and 650 degrees Fahrenheit within 15 minutes of lighting with the lid closed. If the grill is struggling to reach temperature, check that all burners are fully lit and that the gas supply is fully open.