Question 1

after the latest firmware update, my grill's fan sounds different and way louder. did it break itself?

Accepted Answer

DIAGNOSIS It didn't break, it's likely behaving as programmed. Weber has released firmware updates for the EX4 that intentionally changed the fan speed profiles, often making the fan run at higher RPMs more consistently to improve temperature stability and reduce flame-outs. FIX There's no rollback option for firmware, so this is the new normal. The fix is an adjustment of expectations—the grill is now operating as intended by the latest software. The louder, more constant fan noise is a trade-off for (theoretically) more reliable performance, especially at lower 'Smoke' settings. IF THAT DIDN'T WORK If the new sound is a grinding, rattling, or buzzing rather than just a louder whoosh, the increased demand from the new firmware may have exposed a pre-existing weakness in your combustion fan motor or its housing. In that case, the motor might be on its way out and the noise is a coincidence with the update. HEADS UP Don't ignore new, truly mechanical noises. While the fan profile is louder, it shouldn't sound unhealthy. If it's a bad bearing or something is loose, running it could lead to a motor failure mid-cook. If in doubt, call Weber support—they have logs of what the firmware changed and can advise if your noise is within spec.

Question 2

the startup cycle takes forever and sometimes fails with an 'igniter' message. do i need a new igniter?

Accepted Answer

DIAGNOSIS Probably, but not definitely. A slow or failed ignition is often due to poor airflow over the hot rod igniter, starving it of oxygen. This is frequently caused by a pile of ash or unburned pellets covering it. FIX Let the grill cool completely and unplug it. Remove the heat diffusers and flavorizer bars to access the fire pot. Use a shop vac to suck out ALL ash and debris from the pot. Now, locate the metal loop of the igniter at the bottom of the pot. Clear any material touching it. There should be a clear space around it. This simple cleaning fixes most 'igniter' issues. IF THAT DIDN'T WORK If it's clean and still fails, the igniter itself might be weak. You can test it: during the next startup cycle, look through the hole in the diffuser at the fire pot. You should see the igniter glowing bright orange within a few minutes. If it's dull red or not glowing at all, it's failing and needs replacement. HEADS UP Never use compressed air to clean the fire pot. You'll just blow fine ash into the fan and auger motor, causing bigger problems. Always vacuum. Also, using cheap, dusty, or oversized pellets can create more ash that smothers the igniter faster.

Question 3

grease is pouring out from under the grill and down the legs, not into the cup. what did i do wrong?

Accepted Answer

DIAGNOSIS You didn't do anything wrong; this is the infamous 'grease waterfall' issue, especially on early cooks or with fatty meats. The grease is missing the collection chute and running down the inside of the back panel. FIX The primary fix is to ensure the grease management ramp is installed correctly and is *level*. Turn the grill off and cool. Remove the flavorizer bars and heat diffusers. The metal ramp that should direct grease to the chute can get misaligned. Bend it gently so it sits perfectly flat and leads directly into the hole for the grease chute. Also, make sure the rubber gasket on the grease chute itself is present and seated. IF THAT DIDN'T WORK If the ramp is aligned but grease is still leaking, the grill might not be level front-to-back. Use a spirit level on the cooking grates. The grill needs a very slight tilt backwards so gravity pulls grease toward the chute. Adjust the wheels or legs until you get that slight rearward tilt. HEADS UP Never let the disposable grease cup overflow. It will wick grease back up the chute and make the internal leakage worse. Check it every cook, and replace it before it's more than half full. A full cup is a major fire hazard.

Question 4

my smokefire just shut down in the middle of cooking and now it won't turn back on, no lights, nothing.

Accepted Answer

DIAGNOSIS A total, sudden power loss like that points directly to the safety thermal fuse. It's a one-time fuse on the control board that blows if things get too hot inside the electronics housing, often from grease accumulation or a failed fan. FIX You'll need to access the control board. Unplug the grill and let it cool. Remove the hopper assembly (a few screws). Locate the small, white ceramic fuse on the board. Test it with a multimeter for continuity—if it's blown (no continuity), it needs replacing. It's a standard 250V, 10A, 277-degree thermal fuse you can find online. IF THAT DIDN'T WORK If the fuse is intact, the problem is further back. Check the main power cord where it enters the base for any obvious damage or melting. Also, check the internal wiring harness connections to the control board—a loose connector from vibration can cause a total blackout. HEADS UP Replacing the fuse is a temporary fix if you don't address why it blew. Before reinstalling everything, thoroughly vacuum out any grease, dust, or pellet debris from inside the base and around the control board and fan. A clogged fan intake is a common cause of the overheating that blows the fuse.

Question 5

the temperature on my ex4 is swinging wildly, like +/- 50 degrees from where i set it. is it broken?

Accepted Answer

DIAGNOSIS Big temp swings are usually a symptom, not the root cause. The most common culprit is a dirty or faulty temperature probe inside the cooking chamber, which makes the controller freak out and over/under-feed pellets. FIX Locate the ambient temperature probe (it's a metal rod on the left side wall, near the top). Let the grill cool completely, then unplug it. Scrub the probe aggressively with a ball of crumpled-up aluminum foil or very fine steel wool until it's shiny metal again. Grease and soot insulate it, giving false readings. IF THAT DIDN'T WORK If cleaning the probe doesn't stabilize things, check the rubber gasket around the hopper lid. If it's torn or missing, it can let in excess air that the controller can't account for, causing surges. Also, ensure the grease management system (the chute and cup) is clear—a major grease blockage can cause flare-ups that spike the temp. HEADS UP Don't trust the built-in probe calibration if the physical probe is filthy. Always clean it first. Also, these grills are sensitive to wind; using it on a very windy day without some shelter will almost guarantee temp instability no matter what.

Question 6

i can't get my grill to connect to the app, it just spins forever. my phone's bluetooth and wifi are on.

Accepted Answer

DIAGNOSIS The setup process for the Weber Connect app is notoriously finicky. The most likely cause is that your phone is trying to connect to your 5GHz home WiFi network during setup, which the grill's module doesn't support. FIX Force your phone onto your network's 2.4GHz band before starting. The surefire way is to go into your phone's WiFi settings, 'forget' your home network, then re-join it. When it asks, explicitly choose the 2.4GHz option (often has a slower speed listed). Then, with the grill on and in connectivity mode, restart the app setup process from scratch. IF THAT DIDN'T WORK The next step is a full module reset. On the grill's controller, hold down the 'WiFi' and 'Feed' buttons simultaneously for about 10 seconds until the display resets. This clears the grill's network memory. Then try the setup again, making sure your phone is still on 2.4GHz. HEADS UP The grill only broadcasts its setup network for a few minutes. If you take too long, it times out. If the grill's display stops showing the setup icon, turn the dial to 'OFF', wait 30 seconds, and turn it back on to 'SMOKE' to make the network reappear before trying on your phone again.

Question 7

why does my smokefire make a loud, repetitive clicking noise from the hopper when i'm not even using it?

Accepted Answer

DIAGNOSIS Yeah, this one's common and freaks people out. That's the auger doing a periodic reverse cycle. It's a programmed feature, not a bug, to prevent a 'heat bridge' from forming in the pellet hopper. FIX This is normal operation, so there's nothing to 'fix.' The controller runs the auger in reverse for a few seconds every so often if the grill is plugged in but in standby mode, to keep the pellets loose. You can make it stop by simply unplugging the grill from the outlet when you're done cooking. IF THAT DIDN'T WORK If the clicking is constant, erratic, or happening while you're trying to cook, that's a different problem. It could mean the auger motor is struggling against a jam or failing. In that case, you'd need to power down, empty the hopper, and check for a pellet jam in the auger tube. HEADS UP Don't ignore a true constant grinding or straining noise *during* a cook. That's the auger motor potentially burning itself out trying to push pellets, and you'll need to shut it down to investigate a jam or faulty motor before it fully fails.

Question 8

my smokefire ex4 just shows 'err' on the screen and won't start up, what's going on?

Accepted Answer

DIAGNOSIS That's the controller's catch-all error state. It usually means the auger motor or the fan motor is failing to initialize on startup, which is a pretty common hiccup with these. FIX First, do a hard reset. Unplug the grill from the wall, then also disconnect the controller cable from the back of the unit itself. Wait a full minute. Plug the controller cable back in firmly, then plug the power cord back in. If the 'ERR' is gone, try starting it normally. If it persists, the issue is likely a failed motor component that needs replacement. IF THAT DIDN'T WORK If the hard reset clears the code but it comes back when you try to ignite, the problem is often the combustion fan. Listen closely during startup—if you don't hear the fan whirring to life, that's your culprit. It's a known failure point and a replacement part you can install. HEADS UP Don't just keep trying to start it over and over. If the fan or auger isn't working, you'll just flood the fire pot with pellets, creating a big, stubborn mess you'll have to vacuum out before you can try any fix.

Weber SmokeFire EX4 2nd Gen Pellet Grill

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