Boneless Pork Loin Roast Grill Recipe: Smoky Char With Herb-Crusted Depth

Getting my first whiff of hickory smoke always takes me back to family cookouts. This recipe brings that same smoky depth to a boneless pork loin, with a simple herb crust that locks in moisture.

I’ve found that grilling over indirect heat ensures even cooking without drying out the meat. The result is a tender, flavorful roast with a perfect char, every time.

Ingredients for Boneless Pork Loin Roast Grill

Pantry staples meet fresh herbs for a pork roast with serious smoky character.

[recipe_ingredient_scaler]

The pork loin is the star—look for even marbling at the butcher counter or Whole Foods meat section. A 2-pound roast feeds four with leftovers. Hickory chips are essential for that authentic smoke flavor; Lumberjack or Weber brands both work well. Fresh herbs make a huge difference here, so grab them from the produce section rather than the dried aisle (the good stuff, not the pre-shredded kind).

No fresh herbs? Dried at one-third the amount works in a pinch, but fresh really shines. Out of Dijon? Whole-grain mustard adds texture, or regular yellow mustard in a bind. For the wood chips, apple or cherry wood gives a milder smoke if you prefer subtlety. The brown sugar can be swapped for maple syrup (use 1.5 tbsp for the same sweetness).

The herb crust can be mixed ahead (trust me on this)—store covered in the fridge for 24 hours. Cooked pork keeps beautifully, wrapped tight, for 4-5 days in the fridge. Leftovers make killer sandwiches or tacos.

Step-by-Step Instructions for Boneless Pork Loin Roast Grill

Here’s the method I use to achieve that perfect smoky char with a fragrant herb crust every time.

Step 1: Prepare the Herb Crust and Prep the Pork

In a small bowl, combine the 2 tbsp Fresh Rosemary, 2 tbsp Fresh Thyme, 4 cloves Garlic Cloves, 2 tbsp Dijon Mustard, 2 tbsp Olive Oil, 1.5 tsp Kosher Salt, 1 tsp Black Pepper, 1 tsp Smoked Paprika, 1 tbsp Brown Sugar, and 1 tbsp Apple Cider Vinegar. Stir until it forms a thick paste. This is your herb crust that will create an incredible flavor seal.

Pat the 2 lb Boneless Pork Loin completely dry with paper towels—this helps the crust adhere and promotes even browning. Trim any excess fat, then rub the herb mixture all over the surface, pressing it in firmly so it creates a thick, even coating.

Step 2: Set Up Your Grill for Indirect Heat

Soak the 1 cup Hickory Wood Chips in water for 30 minutes to prevent them from burning up too quickly. While they soak, preheat your grill to medium-high heat (about 375-400°F). For a charcoal grill, bank the coals to one side. For a gas grill, turn off the burners on one side.

Drain the wood chips and place them in a smoker box or wrap them in heavy-duty foil with holes poked in the top. Position this directly over the heat source. You want the wood chips to smolder and produce smoke, not burst into flames. Close the lid and let the grill stabilize with smoke building inside.

Step 3: Sear and Smoke the Pork Loin

Place the pork loin on the grill over the direct heat side first. Sear for 3-4 minutes per side until you’ve developed a deep, golden-brown crust. This initial sear locks in juices and creates that beautiful char we’re after.

Move the pork to the indirect heat side of the grill, away from the flames. Close the lid and let it smoke for 1 to 1.5 hours, or until the internal temperature reaches 145°F. Maintain the grill temperature between 275-300°F throughout cooking.

Step 4: Rest and Slice for Maximum Juiciness

Once the pork reaches 145°F internally, transfer it to a cutting board and tent loosely with foil. Let it rest for 10-15 minutes—this allows the juices to redistribute throughout the meat. If you skip this step, you’ll lose much of that precious moisture when you slice into it.

Slice the pork against the grain into ½-inch thick pieces. Each slice should showcase that beautiful herb crust on the outside and perfect, juicy pork on the inside. The meat should be slightly pink in the center but cooked through.

Regional Styles of boneless pork loin roast grill

Texas Style

In the Lone Star State, we keep it simple but bold. I use a dry rub of 2 tbsp smoked paprika, 1 tbsp brown sugar, and 1 tbsp kosher salt instead of the herb crust. The smoke from post oak wood gives that authentic Texas flavor. 🔥

Carolina Pull

For a Carolina twist, I swap the herb crust for a vinegar-based mop sauce applied during cooking. Use 1 cup apple cider vinegar, ¼ cup brown sugar, and 1 tbsp red pepper flakes for that tangy kick. Shred the pork after grilling for pulled pork sandwiches.

Memphis Dry Rub

Memphis-style means a heavy dry rub with no sauce. I combine 2 tbsp paprika, 1 tbsp garlic powder, 1 tbsp onion powder, and 1 tsp cayenne. Apply generously before grilling and serve with pickles and white bread.

Kansas City Sweet

Here we embrace sweetness. I brush the pork with a mix of ½ cup ketchup, ¼ cup molasses, and 2 tbsp apple cider vinegar during the last 30 minutes of grilling. The sugar caramelizes beautifully over the smoke. 💛

Cajun Spice

For a Louisiana flair, I create a Cajun paste with 2 tbsp Cajun seasoning, 1 tbsp Dijon mustard, and 1 tbsp olive oil. The blend of spices like thyme, oregano, and cayenne adds serious heat and complexity to the pork.

Frequently Asked Questions