Grilling Italian Sausage to Perfection: A Guide to Cook Times

Juicy, flavorful Italian sausage hot off the grill is a beloved summer tradition. The aroma of sizzling sausage and smoky char is the scent of backyard cookouts and fun with family and friends. But to enjoy the perfect grilled Italian sausage, it’s key to know exactly how long to cook it. Undercooking can lead to safety issues, while overcooking yields dried out, tough sausage.

In this comprehensive guide, we’ll cover everything you need to know about achieving ideal cook times and doneness when grilling Italian sausage. You’ll learn techniques, tips and tricks from grill masters so you can serve platters of plump, tasty sausages all summer long.

Factors that Influence Grill Time

Before we dive into specifics on cook times it helps to understand what impacts the time needed to grill Italian sausages

• Grill temperature – Hotter heat means faster cooking. Keep the temp at medium heat between 375-400°F.

• Thickness – Thicker sausages take longer to cook than thin ones. Allow more time for jumbo sausage links

• Raw or precooked – Precooked or partially cooked sausages take less time on the grill.

• Grilling method – Direct heat grills faster than indirect heat. Indirect heat requires more time but prevents burning.

• Type of sausage – Flavors like cheese or sun-dried tomato cook faster than traditional Italian sausage.

Now let’s explore exactly how long to grill each type of Italian sausage to reach safe doneness.

Grilling Times for Raw Italian Sausage

Raw Italian sausage sold in links or bulk is the most common type you’ll find. Here are guidelines for grilling raw Italian sausage:

• 2-inch links – Grill for 14-18 minutes total. Flip occasionally to prevent burning.

• 4-inch links – Cook for 18-22 minutes total, flipping sausages as needed.

• 1-inch thick patties – Grill approximately 8-12 minutes per side. Flip once halfway through.

• Thick 2-inch sausages – Cook for around 22-28 minutes, turning to grill all sides. Monitor carefully to prevent charring.

Use tongs to flip sausages gently. Turning too often can cause juices to escape.

Achieving Proper Internal Temp

Regardless of shape or size, raw Italian sausage must reach an internal temperature of 160°F on the grill to be safe to eat. Insert an instant read thermometer into the thickest part of sausages to check doneness after cooking.

If needed, move sausages to cooler zone of grill to bring temp up without overcharring.

Cook Times for Precooked and Smoked Sausage

Precooked or smoked sausages just need a quick sear on the grill to finish. Follow these guidelines:

• Precooked Italian sausage links – Grill for 6-8 minutes total, turning occasionally.

• Smoked sausages – Grill approximately 8-10 minutes to heat through without burning casing.

Precooked sausages are fully safe to eat, so cooking is just to char and heat. A sear time of 6-8 minutes per side is sufficient.

Grilling Tips for Perfectly Cooked Sausage

Now that you know approximate grill times, here are some tips to ensure you turn out plump, juicy sausages:

• Let sausages sit at room temp for 30 minutes before grilling for more even cooking.

• Use indirect heat to cook thoroughly without burning.

• Brush with oil to prevent sticking. Olive oil or avocado oil work well.

• Prick sausages with a fork before grilling if concerned about bursting.

• Turn sausages every 5-7 minutes for uniform browning.

• Move sausages to upper rack if flare ups occur.

• After grilling, let sausages rest 5 minutes before serving to allow juices to redistribute.

With the proper technique, it’s easy to deliver perfectly cooked Italian sausage every time.

How to Tell When Sausage is Done Grilling

The best ways to gauge doneness:

• Use an instant read thermometer to check internal temp reaches 160°F.

• Cut into a sausage to inspect inside is no longer pink.

• Look for plump, even browning with nice grill marks. Burnt or shriveled means overcooking.

• Check juices run clear rather than pink when cut into.

Following the recommended grill times in this guide will ensure sausages cook through fully without drying out.

Common Grilling Mistakes to Avoid

It’s easy to go wrong when grilling Italian sausage. Be sure to avoid these common pitfalls:

• Grilling at too high temperature which chars outside before inside cooks.

• Undercooking which can cause foodborne illness. Always check internal temp.

• Cutting sausages to check doneness too early which dries them out.

• Piercing sausages repeatedly with a fork which allows juices to escape.

• Leaving uncooked or precooked sausages at room temperature too long before grilling.

With practice, you’ll learn the ideal times and temperatures tailored to your grill and sausages.

Frequently Asked Questions About Grilling Italian Sausage

Let’s answer some common questions on getting perfect grilled Italian sausage:

Should I parboil sausages first?

Parboiling is not necessary if grilling over medium indirect heat and using a meat thermometer to confirm doneness.

Do I have to prick sausages before grilling?

Pricking with a fork prevents splitting but isn’t mandatory. Try dry poking a few tiny holes.

How do I avoid burnt, shriveled sausages?

Use medium indirect heat around 375°F. Move sausages to upper rack or cooler side of grill if flare ups occur.

Can I get crispy sausages without overcooking?

Yes! Sear over direct high heat for 1-2 minutes per side just at the end of grilling to add crispness.

What’s the best way to reheat grilled sausage?

Wrap in foil and reheat in a 300°F oven for 15-20 minutes until heated through. Microwaving makes texture rubbery.

Should I grill sausage on foil?

Grilling directly on the grill grate gives the best sear and flavor. Use foil pouches only if sausages are very fatty and prone to flare ups.

Boldly Flavor Your Sausage

While traditional Italian sausage is always a favorite, don’t be afraid to branch out with fun flavors:

• Spicy chorizo – Imparts a fiery kick.

• Kielbasa – Delivers a touch of smoky garlic flavor.

• Cheese-filled – Oozes melty cheese when cooked.

• Sun-dried tomato and basil – Infuses a fresh herbaceous taste.

The grill times remain similar when using these gourmet sausage varieties. Just adjust cooking based on any fillings or smaller sizes.

Perfectly Grilled Sausage Awaits

Now you have all the knowledge needed to achieve Italian sausage grilling greatness. Follow these guidelines on cook times, temperature and techniques for your best grilled sausages yet.

Be sure to use a food thermometer for safety and test doneness by slicing into sausages. Soon you’ll be an expert on cooking Italian sausage on the grill from start to finish.

Backyard cookouts, tailgates and summer nights just got more delicious. Fire up the grill and look forward to enjoying juicy, crispy sausages all season long. Buon appetito!