Apple POWERBOOK G4 Service Source

 Service Source PowerBook G4 (17-inch 1.33GHz) 16 September 2003

 Service Source Take Apart PowerBook G4 (17-inch 1.33GHz)

General Information Overview Some key features that distinguish this computer from the previous 17-inch PowerBook: PowerBook G4 (17-inch 1.33GHz) PowerBook G4 (17-inch) Microprocessor 1.33GHz 1GHz L2 Cache (on-chip) 512K 256K Graphics Chip ATI Mobility Radeon 9600 nVidia GeForce4 420 USB 2.0 1.0 SuperDrive 2x DVD write 1x DVD write

New Procedures Flex cable compatibility The sound and modem flex cables are not interchangeable with the original PowerBook G4 (17-inch) system. The main logic board will be damaged. The correct flex cables have the word “POWERBOOK G4 17" 1.33GHZ ONLY.” No L3 cache L3 cache is not used on this system. So unlike the previous model, there is no blue thermal pad on the logic board facing the keyboard. Thermal module interface Thermal gel is now used on the ATI Mobility Radeon 9600 graphics chip as well as the Intrepid chip. The thermal module is different from the previous 17-inch PowerBook. It has a different interface feature for the graphics chip and now has three heat pipes instead of one. Important Notes • If a flex connector has a plastic film located on the top that can be lifted up on one side, use it to carefully pull up and wiggle the connector from side to side to disconnect it. Otherwise rock the connector from side to side to disconnect. • The AirPort Extreme card assembly has a flex cable glued to the card, making it unique and specific to this computer. Tools The following tools are recommended for the take apart procedures. • ESD wrist strap and mat • Soft cloth • #00 Phillips screwdriver (magnetized) • #0 Phillips screwdriver (magnetized) • #1 Phillips screwdriver (magnetized) • 4 mm socket wrench • Needlenose pliers • Torx T6 screwdriver • Torx T8 screwdriver • Razor knife • Black stick (nylon probe tool 922-5065) (or other nonconductive nylon or plastic flat- blade tool) • Multi-compartment screw tray (such as a plastic ice cube tray) • Kapton® tape • Voltmeter (for troubleshooting) • Small low-power magnet (for troubleshooting) • Apple Pro keyboard and mouse (for troubleshooting)

Serial Number Location The serial number is located in the battery bay.

Zero Insertion Force Connectors Zero insertion force (ZIF) connectors are used in several locations in the computer. Important: The locking bar on the ZIF connector is extremely fragile and is not intended to separate from the connector. When releasing a bar, use extreme care and a restrained light pressure to move the bar only slightly. Warning: If a locking bar breaks, you will need to replace the board. To release the flex cable Use a flat-blade tool to move the bar on both sides.

To connect a flex cable Make sure the locking bar is released, then slide the end of the flex cable all the way into the connector. Hold the cable in place, then slide the locking bar into the connector on both sides to secure. Important: Verify that the cable is straight. Use either the alignment mark, if present, or the metal edge on the cable as a guide to ensure the cable is straight. Warning: If the flex cable is inserted crooked, some signals may not be connected or signals may short together (a bad connection is shown below.) Note: If a cable is not securing properly, verify that it is inserted on the correct side of the locking bar.

Feet Feet Tools This procedure requires the following tools: • Foot kit • Tweezers or needlenose pliers • Soft cloth Preliminary Step Before you begin, check the bottom case of the computer and compare it with the images in this table. Make sure the foot you want to replace has an intact plug on the bottom case. Plug Area on Bottom Case Matching Foot Action Missing plug Not available for replacement Replace the bottom case, or send the computer to the Apple Repair Center for repair. Plug (either one) Foot Continue with the procedure, matching the replacement foot to either plug on the bottom case.

Feet Procedure Warning: The glue used in this procedure can bond instantly to skin. Do not touch the glue. In the event of contact, review the safety instructions at the end of this section. For additional information, refer to the glue manufacturer: Elmer's Products, Inc. Columbus, OH. 43215-3799 www.krazyglue.com 1. Place the computer upside down on a clean, lint-free cloth or other nonabrasive surface. 2. Make sure the plug area on the bottom case is clean. If any portion of the soft rubber foot remains, remove it so that only the hard plastic plug is visible (as shown with both types of plugs below). Important: Notice the recessed hole in the center of the plug. When positioning the foot, make sure the raised bump on the textured plane of the rubber foot fits into the center hole in the plug. This ensures a balanced and level fitting.

Feet 3. Warning: GLUE IS AN EYE AND SKIN IRRITANT. BONDS SKIN INSTANTLY. Do not touch the glue at any time. Before opening the glue, review the safety instructions at the end of this section. Important: The glue tube included in the kit is sealed until first use. Do not break the seal until you are ready to use the glue. To break the seal, hold the tube upright and away from you. Place the hollow nozzle cap on the tube and tighten it all the way down. The tube is then ready to dispense the glue through the nozzle cap. 4. Apply one drop of glue to the plug on the bottom case. Do not spread the glue. 5. Using tweezers or needlenose pliers, carefully position the new foot so it is centered over the plug, and its integral bumps fit into the compatible holes in the plug. 6. Using the end of the tweezers or pliers—not your finger—lightly press and hold the foot in place for 30 seconds. 7. Before turning over the computer, allow the glue to set for at least 15 minutes. 8. Discard the tube of glue. SAFETY INSTRUCTIONS: GLUE IS AN EYE AND SKIN IRRITANT. BONDS SKIN INSTANTLY. Contains ethyl cyanoacrylate. Avoid contact with skin and eyes. If eye or mouth contact occurs, hold eyelid or mouth open and rinse thoroughly but gently with water only for 15 minutes and GET MEDICAL ATTENTION. Liquid glue will sting eye temporarily. Solidified glue may irritate eye like a grain of sand and should be treated by an eye doctor. If skin bonding occurs, soak in acetone-based nail polish remover or warm soapy water and carefully peel or roll skin apart (do not pull). Contact through clothing may cause skin burn. If spilled on clothing, flush with cold water. Avoid prolonged breathing of vapors. Use with adequate ventilation. KEEP OUT OF REACH OF CHILDREN.

Battery Battery Tools This procedure requires the following tools: • Soft cloth Part Location Preliminary Steps Warning: Always shut down the computer before opening it to avoid damaging its internal components or causing injury. After you shut down the computer, the internal components can be very hot. Let the computer cool down before continuing.

Battery Procedure Warning: If the computer has been recently operating, allow it to cool down before performing this procedure. 1. Shut down the computer. 2. Disconnect the power cord and any other cables connected to the computer. 3. Place the computer face down on a soft cloth. 4. Slide both battery latches away and lift the battery out of the battery bay.

Memory Door and Memory Cards Memory Door and Memory Cards Tools This procedure requires the following tools: • Soft cloth • #0 Phillips screwdriver Part Location Preliminary Steps Before you begin, remove the battery.

Memory Door and Memory Cards Procedure Warning: If the computer has been recently operating, allow it to cool down before performing this procedure. 1. Place the computer face down on a soft cloth. 2. Remove the three screws from the memory door. Note: Check for lost screws caught by magnets inside the front edge of the battery well. 3. Lift the memory door up slightly and slide it straight back to remove.

Memory Door and Memory Cards Note: If only one memory card is installed, it’s factory installed in the top memory slot (nearest to outside edge of the computer). 4. To remove either memory card, first release it by spreading apart the tabs in the memory slot from the notches in the card until the card pops up slightly. 5. Pull the card straight out of the memory slot.

Memory Door and Memory Cards 6. Align the notch in the board with the tab in the slot and insert the replacement memory cards at a 30-degree angle, pushing the card firmly until fully seated. 7. Check that the notches in the card clear the tabs as you press down on the sides of the card to lock it into place.

Memory Door and Memory Cards 8. To reinstall the memory door, hold it at a low angle to the battery bay and slide it in under the back edge, then lay it flat. If the door springs up and does not lay flat without tension, remove it and reinstall at a lower angle.

Memory Door and Memory Cards 9. Install the memory door screws. Note: Before securing, check that the door edge rests flush and inside the ridge. 10. Replace the battery. 11. Use Apple System Profiler to verify that the memory is recognized. (Choose the menu bar Apple logo () > About This Mac, click More Info..., select the System Profile tab, open the Memory Overview.)

Top Case Top Case Tools This procedure requires the following tools: • #0 Phillips screwdriver (magnetized) • #1 Phillips screwdriver (magnetized) • Torx T8 screwdriver (magnetized) • Black stick (or other nonconductive nylon or plastic flat-blade tool) • Soft cloth • Multi-compartment screw tray (21 screws to remove the top case) Part Location

Top Case Preliminary Steps Before you begin, remove the following: • Battery • Memory door • Lower memory card (nearest to battery bay), if present Procedure Note: This procedure removes the top case and keyboard assembly. The keyboard is attached to the top case and is not removed. 1. Place the computer face down on a soft cloth. 2. Remove the three screws inside the battery bay. Note: These screws are shorter than on the memory door. Use care not to lose the screws into holes along the battery bay. Note: Check for lost screws caught by magnets inside the front edge of the battery well. 3. Remove the five screws along the back edge (the two outside screws are longer and have “shoulders”). 4. Remove the two screws on the logic board.

Top Case 5. Locate the top case flex cable and ZIF connector. 6. Very carefully disconnect and remove the cable from the connector. Important: The ZIF connector and locking bar are fragile and can easily break if too much force is used. (See “Zero Insertion Force Connectors” heading.)

Top Case 7. Open the display and place the computer on its side. 8. Remove four side screws from both sides.

Top Case 9. Turn the computer over. 10. Pull up on the top case along the sides and front until it releases. Note: A black stick inserted and twisted under the top case seam may be helpful.

Top Case Replacement Procedure Note: If replacing the top case, remove the keyboard and transfer it to the replacement top case. 1. Visually check to verify that all cables (highlighted below) are connected and routed correctly with nothing raised up or incorrectly over a component. 2. Check perimeter wiring, where shown, to verify that it will not be caught or pinched by the top case during replacement.

Top Case 3. Check that display cable brackets are properly seated and secured with screws. 4. Verify that cables for Bluetooth, AirPort Extreme, inverter and power cable from the DC-in board are routed and seated correctly in channels around the left speaker.

Top Case 5. Verify that the LVDS cable’s metal bead fits into the metal channel (rounded side up so that its teeth secure it) and that the cable is secured into the channel along the right speaker. 6. Verify that the sleep LED wires route over the notch in the frame (secure with Kapton tape) and along the inside channel away from the front edge so that it will not be damaged when replacing the top case.

Top Case 7. On the top case, check cable connections and routing. 8. Check that the perimeter metal tabs are not bent. Note: Do not bend the tabs; the metal quickly fatigues and can break off easily.

Top Case 9. Lay the top case upside down and locate the flex cable. 10. While pulling the cable up, run a finger along its base to crease it at a 90-degree angle. 11. The cable should point straight up.

Top Case 12. Open the display to 90-degrees and tilt the computer back so it rests on the back of the display. 13. Guide the top case flex cable through the slot between the logic board and the bottom case frame.

Top Case Note: For the following procedures, you will want to keep the top case close to the bottom case so the flex cable will not pull out of the slot. 14. Turn the computer to rest on the bottom case. 15. At the left front corner of the computer, insert the top case edges into the bottom case channels, shown. 16. Hold the front of the top case along the front edge of the bottom case and lower into place.

Top Case 17. Note: If the tabs along the sides of the top case catch on the bottom case, use a narrow tool and work from front to back to carefully push or pull the tabs very slightly to help slide them into place. Important: The tabs are fragile. Do not apply too much pressure or bend them. Note: Some side screws have a flexible screw boss. If they block a tab from seating, use a narrow tool to push the boss slightly.

Top Case Important: The top case should lay flat along the sides and top, if not, make sure that cables and components are not interfering. Also, make sure it is not held up by one of the metal tabs protruding down from the top case. Carefully bend them slightly to fit if needed. 18. Install the front and rear side screws on both sides to hold the top case in place.

Top Case 19. Carefully close the display, without forcing. If it does not close easily, reinstall the top case, checking for cable routing and clearances. 20. Turn the computer over. 21. Check that the top case flex cable is still through the slot. If not, use the round shaft of a small Phillips screwdriver to carefully pull it through, as shown. Important: If the cable does not fully reach the ZIF connector, the cable is trapped under the frame. Reinstall the top case.

Top Case 22. Carefully pull the locking bar of the ZIF connector out slightly. Slide the flex cable over the locking bar and into the connector until it stops (the metal edge of the cable should be parallel to the connector), then slide the locking bar in to secure it. 23. Check for a gap, as shown below, between the top and bottom case at the back right side next to the hinge. This may indicate that the LVDS cable is trapped.

Top Case 24. To check this, insert the flat-blade side of a black stick between the display and top case then push toward the bottom case to see if the gap can be closed. If so, proceed to next step. If not, remove the top case and check the routing of the LVDS cable, then reinstall the top case. 25. Carefully install one of the “shoulder” screws in the end screw hole on the bottom. Important: If the screw does not go in easily do not force it or damage may result. Check the routing of the LVDS cable and reinstall the top case.

Top Case 26. Install the other “shoulder” screw in the end screw hole. 27. Install the remaining side screws. 28. Install the logic board screws. 29. Install the remaining bottom screws along the back edge. 30. Install the memory door, and screws. 31. Install the battery bay screws. 32. Visually check the flatness of the top case. If it is not flat, remove it, fix the problem, then reinstall. 33. Replace the battery. 34. Testing the computer should include powering on, checking the keyboard and trackpad function, and operate the computer in a dimly lit room to check that the keyboard backlight is working.

Keyboard Keyboard Tools This procedure requires the following tools: • #0 Phillips screwdriver • Torx T8 screwdriver (or other blunt tool, 3.5mm wide or less) • Black stick (or other nonconductive nylon or plastic flat-blade tool) Part Location Preliminary Steps Before you begin, remove the following: • Battery • Top case

Keyboard Procedure 1. Turn the top case over, locate the keyboard flex cable and remove the Kapton tape holding the cable. 2. Carefully release the locking bar of the cable’s ZIF connector and pull out the cable. 3. Locate and carefully peel off the insulator film over keyboard screws and reserve for reinstallation.

Keyboard 4. Remove remaining adhesive, if any, from the top case and screw heads. 5. Remove the fourteen identical screws. 6. Start at the power button side and use a blunt tool (no wider than 3.5 mm) to carefully push on the keyboard screw bosses through the boss holes to begin to release the keyboard from its adhesive. Important: To avoid damaging the screw boss threads, do not use a narrow tool that will fit into the screw hole.

Keyboard 7. Continue until the keyboard can be grasped, then carefully lift it up and guide out its flex cable (shown below).

Keyboard 8. Carefully rub off any adhesive residue left in the keyboard well and on the fiber optics.

Keyboard Replacement Procedure 1. To install the keyboard or replacement keyboard, insert its flex cable through the slot in the top case and rest the bottom of the keyboard evenly along the bottom edge of the keyboard well. 2. Remove the protective cover from the adhesive strips on the keyboard. While keeping the bottom of the keyboard flush along the bottom, lay the keyboard into place so that the screw bosses fit into the boss holes. 3. Install the keyboard screws. 4. Replace the insulator film, avoiding wrinkles or bulges. Important: The film must be installed and in the same location to protect against contact and electrical shorting in certain areas and to allow contact with the EMI spring on the logic board.

Keyboard 5. If replacing the existing keyboard, such as during a top case replacement, secure the end of the keyboard flex cable. (The cable inserts under the ZIF connector locking bar.) 6. If installing a replacement keyboard, first remove the cable’s adhesive protector, then turn the cable under itself (so the adhesive is on the inside of the loop but do not secure the adhesive). Secure the end of the keyboard flex cable into the ZIF connector. (The cable inserts under the ZIF connector locking bar.)

Keyboard 7. Fold the cable flat and secure it’s adhesive by firmly holding the left side (to prevent cable movement) while sliding your right hand fingers forward on the right side. 8. Use Kapton tape to secure the cable flat at the fold.

Keyboard 9. Verify that the cable is still fully inserted, straight and secure in the connector. 10. Turn over the top case and inspect the left and right sides of the keyboard. Push any Mylar down along the sides of the keyboard. 11. Reassemble the computer. 12. Testing the computer should include powering on, checking the keyboard and trackpad function. In a darkened room, check for keyboard backlight function, and light leakage around the perimeter of the keyboard, speaker grill openings and side ports.

Hard Drive Hard Drive Tools This procedure requires the following tools: • Torx T8 screwdriver (magnetized) • #1 Phillips screwdriver (magnetized) Part Location Preliminary Steps Before you begin, remove the following: • Battery • Top case

Hard Drive Procedure Important: Use the tab that can be lifted on the top of the connector on one side, if present, to carefully wiggle the connector from side to side to disconnect it. Otherwise, gently rock the connector from side to side to disconnect. 1. Remove the sound board flex cable. 2. Disconnect the hard drive flex cable. 3. Remove the four screws. 4. Lift out the hard drive (guide the flex cable under the speaker cables if necessary).

Hard Drive 5. Transfer brackets, side screws, rubber shockpads and the flex cable to the replacement hard drive. 6. Install the replacement hard drive, and reassemble the computer. Warning: Make sure the sound board flex cable has a label marked “POWERBOOK G4 17" 1.33GHz ONLY”. 7. Testing the computer should include powering on, checking that the hard drive is recognized, checking for sound from the speakers and that the sleep LED light works.

Sound Board Sound Board Tools This procedure requires the following tools: • Torx T8 screwdriver (magnetized) • Black stick (or other nonconductive nylon or plastic flat-blade tool) Part Location Preliminary Steps Before you begin, remove the following: • Battery • Top case • Hard drive

Sound Board Procedure 1. Disconnect the speaker wires connector and sleep LED connector. 2. Remove the two screws. 3. Pull the sound board out starting at the ports end.

Sound Board Replacement Note: To prevent damage to the sleep LED wires during top case reassembly, verify that the wires route over the notch in the frame (secure with Kapton tape here and over connector) and then along the inside channel away from the front edge. 4. Install the replacement sound board, and reassemble the computer. 5. Testing the computer should include powering on, checking for sound from the speakers and that the sleep LED light works. The headphone and line in ports should be checked.

SuperDrive SuperDrive Tools This procedure requires the following tools: • Torx T8 screwdriver (magnetized) • #1 Phillips screwdriver (magnetized) Part Location Preliminary Steps Before you begin, remove the following: • Battery • Top case

SuperDrive Procedure Important: Use the tab that can be lifted on the top of the connector on one side, if present, to carefully wiggle the connector from side to side (sides indicated) to disconnect it. Otherwise, gently rock the connector from side to side to disconnect. 1. Disconnect the SuperDrive flex cable connector. Warning: Do not pull up on the end of the flex cable connector or the cable may separate from the connector. 2. Remove the four screws. 3. Carefully lift and guide the drive out. Important: Avoid pulling on the backup battery flex cable.

SuperDrive 4. Transfer the flex cable, brackets and screws to the replacement SuperDrive. 5. Install the replacement SuperDrive, and reassemble the computer. 6. Testing the computer should include powering on, inserting a CD and ejecting it to make sure the drive is aligned with the opening and functioning properly.

Backup Battery Board Backup Battery Board Tools This procedure requires the following tools: • Torx T8 screwdriver (magnetized) • Black stick (or other nonconductive nylon or plastic flat-blade tool) Part Location Preliminary Steps Before you begin, remove the following: • Battery • Top case • SuperDrive

Backup Battery Board Procedure 1. Release the two ZIF connectors and remove the flex cable. 2. Remove the three screws. 3. Install the replacement backup battery board. 4. Reassemble the computer. 5. Testing the computer should include plugging in the power adapter and letting the backup battery charge for half an hour. Then power on the computer and disconnect the power adapter, set the system clock, put the computer to sleep, remove the main battery for five seconds and reinstall. The time should not reset. Also, check the right side USB port which is on the backup battery board.

Modem Modem Tools This procedure requires the following tools: • 4 mm socket wrench • Needlenose pliers (helpful to reinstall hex nuts) Part Location Preliminary Steps Before you begin, remove the following: • Battery • Top case Warning: Make sure the modem flex cable has a label marked “POWERBOOK G4 17" 1.33GHz ONLY”.

Modem Procedure 1. Disconnect the modem flex cable. 2. Remove the three hex nuts. 3. Lift the modem up slightly and disconnect the RJ-11 cable connector. 4. Install the replacement modem, and reassemble and test the computer.

PC Card Cage and AirPort Extreme Assembly PC Card Cage and AirPort Extreme Assembly Tools This procedure requires the following tools: • #0 Phillips screwdriver (magnetized) • Torx T6 screwdriver (magnetized) • Black stick (or other nonconductive nylon or plastic flat-blade tool) Part Location Preliminary Steps Before you begin, remove the following: • Battery • Top case • Modem

PC Card Cage and AirPort Extreme Assembly Procedure 1. Turn the computer over and remove the rubber gasket on the AirPort Extreme flex cable connector and reserve for reinstallation. Disconnect the connector. 2. Turn the computer over and disconnect the PC card cage and hard drive flex cables.

PC Card Cage and AirPort Extreme Assembly 3. Pull out the coupling (joining the AirPort Extreme jumper and antenna cable) from the channel in the side of the left speaker. Grasp the coupling (not the wires) at both ends and pull to separate it at the middle. 4. Remove two Phillips screws and two Torx T6 screws.

PC Card Cage and AirPort Extreme Assembly 5. Important: The cross piece at the front end of the PC card cage is fragile. To avoid damage, do not touch this area while maneuvering the assembly. Lift up on the sides of the PC card cage assembly and carefully guide the AirPort Extreme card flex cable connector from under the logic board. Important: To avoid damage, do not allow the pins of the AirPort Extreme card cable connector to rub along the logic board. If the clearance is too tight, try slightly loosening a couple of the logic board screws on this side, but do not bend the board. If this doesn’t work, the logic board will have to be removed to continue. 6. Slide out the PC card cage eject button.

PC Card Cage and AirPort Extreme Assembly 7. Turn over the PC card cage to locate the AirPort Extreme card. 8. Pull on the AirPort Extreme card flex cable to slide the card out of the PC card cage. Note: Wiggling the card from side to side slightly may help to release it. 9. If replacing the AirPort Extreme card, pull the antenna jumper connector straight back to remove it. Transfer the cable extension to the replacement AirPort Extreme card.

PC Card Cage and AirPort Extreme Assembly 10. Install the AirPort Extreme card onto the PC card cage to be installed and reinstall the assembly. Replacement Note: Ensure that the pin on the PC card cage eject button is secured by the hole in the cage mechanism. 11. Reassemble the computer. 12. Testing the computer should include inserting a PC card to check that it can be locked in and that the eject button works smoothly. Use Apple System Profiler to check that the AirPort Extreme card and modem are recognized. Test that the AirPort Extreme card is working and that the modem can dial out.

Bluetooth Bluetooth Tools This procedure requires the following tools: • Torx T6 screwdriver (magnetized) • Black stick (or other nonconductive nylon or plastic flat-blade tool) Part Location Preliminary Steps Before you begin, remove the following: • Battery • Top case.

Bluetooth Procedure 1. Release the two ZIF connectors and move the flex cable aside. 2. Disconnect the Bluetooth antenna cable. Replacement Note: Make sure the antenna cable is secured in the channel on the speaker.

Bluetooth 3. Remove the screw and Bluetooth board. 4. Install the replacement Bluetooth board, and reassemble the computer. 5. Testing the computer should include using Bluetooth to connect to another computer. Check the function of the DC-in port and the left USB port.

Speakers Speakers Tools This procedure requires the following tools: • Torx T8 screwdriver (magnetized) • Black stick (or other nonconductive nylon or plastic flat-blade tool) Part Location Preliminary Steps Before you begin, remove the following: • Battery • Top case • Bluetooth board

Speakers Procedure Note: Lift up any Kapton tape as necessary and reserve for replacement. 1. Pull wires out of routing channels on the left speaker. 2. Remove one screw on each speaker.

Speakers 3. Lift out speakers. 4. Deroute the speaker wires along logic board. Replacement Note: Verify proper routing of speaker cables under securing clips. 5. Disconnect the speaker wire connector from the sound board. 6. Install the replacement speakers, and reassemble the computer. 7. Testing the computer should include using the Sound system preference pane to test the left and right speakers.

DC-In Board DC-In Board Tools This procedure requires the following tools: • Torx T8 screwdriver (magnetized) • Black stick (or other nonconductive nylon or plastic flat-blade tool) Part Location Preliminary Steps Before you begin, remove the following: • Battery • Top case • Left speaker

DC-In Board Procedure 1. Disconnect the RJ-11 connector to the modem. 2. Disconnect the power cable on the DC-in board. 3. Remove the two screws. 4. Insert a black stick under the DC-in board to help guide it out.

DC-In Board Replacement Note: Make sure that the replacement DC-in board includes the RJ-11 port and ambient light sensor cover. If not transfer them from the original board to the replacement board. The RJ-11 port slides off the DC-in board but may be very tight. It may be helpful to pull on the port until it begins to move, then use a black stick to create leverage behind the port. The ambient light sensor cover slides on and is attached with a screw from underneath the board.

DC-In Board 5. Install the replacement DC-in board, and reassemble the computer. Note: Insert a black stick into the USB port opening to guide the board into place. 6. Testing the computer should include using Bluetooth to connect to another computer. Check the function of the modem port, DC-in port and the left USB port.

Logic Board Logic Board Tools This procedure requires the following tools: • Torx T8 screwdriver (magnetized) • 1600 watt hair dryer • Razor knife • Black stick (or other nonconductive nylon or plastic flat-blade tool) • Thermal Pad Kit (076-1033) • T630 thermal gel (922-5929). Note: To organize the screws you remove from the computer, use a tray with divided compartments (such as a plastic ice cube tray). Part Location

Logic Board Preliminary Steps Before you begin run the computer until warm (if possible) to help soften the thermal materials on the logic board, then shut it down and remove the following: • Battery • Top case • SuperDrive • Right speaker Procedure Warning: Flexing of the logic board can break solder joints to chips. To prevent damage to the board, guard against flexing. 1. Turn the computer over. Disconnect the cables shown.

Logic Board 2. Turn the computer over. Disconnect the cables shown. 3. Remove the twelve screws.

Logic Board 4. Important: To prevent damage to the logic board chips, the thermal material between the logic board and the heatsink must be softened before removing the logic board. Use the following procedure: • Remove all memory cards and leave the memory door off. • Verify all screws have been removed. • Verify all cables are disconnected and moved away from the procedure area shown below. • Turn on a 1600 watt hair dryer and set it to high. Move the dryer back and forth continuously, left to right, about one second per cycle, over the area shown below, holding it about 20 mm (about 1-inch) above the board, for approximately one and a half minutes. (The temperature should reach approximately 75-80-degrees C (167-176-degrees F).) • After at least 45-seconds, and while continuing to move the hair dryer as described above, insert a black stick just under the left edge of the logic board, where shown below, and apply slight upward pressure (do not pry). Continue the hair dryer procedure along with the slight upward pressure on the board until the thermal material releases and the board moves up easily. • Once the thermal material has released, discontinue using the hair dryer. • Continue to the next step before the thermal material cools. Warning: Do not use a heat gun, or damage can result.

Logic Board 5. Lift the logic board from the left side and pivot along the port side. Note: The thermal material should easily release. If not, repeat the hair dryer procedure, above (verify that all the screws have been removed). Apply slow constant pressure until it releases, avoid over flexing. Warning: Do NOT flex the board. Give special attention at the narrow neck of the blower cutout.

Logic Board 6. Carefully coax the port end of the board out of the port openings. Note: The DVI connector may catch on the part of the frame shown here. Carefully maneuver it until it releases. Warning: To avoid flexing the logic board, hold the board vertically along the wide sides. Do not hold the board by the ends or by the narrow neck at the blower cutout, or horizontally, as the board’s weight can cause excessive flex.

Logic Board Replacement Procedure 1. Verify that the replacement logic board has EMI shields attached, as shown. If not, transfer the shields from the replaced board, or replace with a new shield kit. 2. Use a black stick to remove all the original thermal material on the heatsink at all three mating surface locations shown below. 3. Vigorously clean remaining residue and adhesive with an alcohol pad.

Logic Board Warning: Whenever the logic board is separated from the heatsink, you must remove all existing thermal material and install new thermal material to the heatsink at the three locations shown above. Failure to do so can cause the computer to overheat and be damaged. Important: Avoid unnecessary contact with thermal pads or gel, as dirt and body oils reduce the thermal pad's conductivity. If thermal pads have a backing material, remove one side before applying to the heatsink. Center that side over the mating surface (raised surface) and evenly apply it, without air pockets, by lightly pressing. Remove any remaining backing. (The picture shown is for illustration only.)

Logic Board 4. Center and install a new thermal pad onto the heatsink where removed, as shown below. Important: If the thermal pad kit includes two same-size pads, apply them, with the backing removed, one on top of the other as a double layer. 5. Apply approximately 0.3 to 0.5 cubic centimeter (cc) of T630 thermal gel (922-5929) to the center of the center mating surface on the heatsink. Note: The 10 cc dispenser may be graduated in milliliters. A milliliter (ml) is the same as a cubic centimeter (cc). Note: To apply the thermal gel from the 10 cubic centimeter (cc) dispenser, remove the end cap and push the plunger until the gel reaches the front opening. Note the position of the end of the plunger in the tube. Dispense the gel until the plunger end moves about 1/3 to 1/2 of 1 cc (ml). The plunger will move back slightly when pressure is released, so push it slightly beyond the amount to be dispensed. 6. On the right mating surface, apply approximately 0.3 cc’s to each of the four outer corners and approximately 0.5 cc’s to the center, as shown.

Logic Board Important: With an razor knife, trim any excess thermal pad material, if any, that extends beyond the mating surface, to prevent it from touching holes in the heatsink. Note: After installing new thermal material, if you must briefly re-separate the logic board from the heatsink, it is OK to retain the same, new material, as long as they are not handled excessively.

Logic Board 7. If the logic board was removed to facilitate another procedure and will be reinstalled, also remove all the thermal material from each of the three corresponding chips (shown below) in the same manner. Important: Use extreme care not to damage the chips or logic board components. 8. To replace the logic board, guide the port side into the port openings on the bottom case. Align the S-video port first. Note: Use care not to catch cables under the board as it is lowered into place. 9. Attach the screws in the order shown. Note: The three screws replaced first have “shoulders” and use wavy washers. Make sure that the washers do not get caught under the shoulder of the screw when installing. 10. Reassemble and test all ports, components and functions of the computer.

Display Panel Assembly Display Panel Assembly Tools This procedure requires the following tools: • Torx T6 screwdriver (magnetized) • Black stick (or other nonconductive nylon or plastic flat-blade tool) • 4 mm socket wrench (to install the pop-up spring torsion bar) Part Location Preliminary Steps Before you begin, remove the following: • Battery • Top case

Display Panel Assembly Procedure Note: During these procedures, remove and reserve any Kapton tape for replacement, or replace with new tape during reinstallation. 1. Carefully disconnect the cable connectors shown. 2. Pull out the coupling (joining the AirPort Extreme jumper and antenna cable) from the channel in the side of the left speaker. Grasp the coupling (not the wires) at both ends and pull to separate it at the middle.

Display Panel Assembly 3. Carefully disconnect the Bluetooth cable connector. Important: During the following procedures, take care that the small parts and screws do not fall inside the computer. 4. Remove the screws that hold the wire brackets at both sides of the clutch barrel.

Display Panel Assembly 5. Move the display to a 90-degree angle and remove the two screws for the end caps of the clutch springs on each side. Note: A 90-degree angle on the display helps to reduce the tension on the end pieces. 6. Remove the two clutch cleat screws on each side of the clutch barrel. Important: Before removing the last screw, support the display so that it does not fall over.

Display Panel Assembly 7. Lift off the display panel and clutch barrel assembly. 8. Remove the clutch spring end caps from both sides.

Display Panel Assembly 9. Remove the two screws and torsion bar on each side.

Display Panel Assembly Replacement Procedure 1. To reinstall the display panel assembly, replace the end caps onto both clutch springs. 2. At the back corners of the bottom case assembly, push the pop-up spring pins all the way back, on both sides.

Display Panel Assembly 3. On the clutch, push the limit stop feet all the way back, on both sides. 4. Lower the display panel assembly straight down onto the bottom case assembly. 5. Verify that the limit stop feet, fit into the holes in front of the pop-up spring pins, on both sides.

Display Panel Assembly 6. Install and tighten the screws for the clutch cleats, on both sides. 7. Hold the display at a 90-degree angle and install the end cap screws on both sides.

Display Panel Assembly 8. To install the pop-up torsion bars, insert the bar so that the notch is behind the pop-up spring pin and install the first screw furthest away from the pin. 9. Then, use a sturdy hex nut driver to press the torsion bar down flat (this places tension on the pop-up spring pin) and install the second screw. Do this for both sides.

Display Panel Assembly 10. Replace the wire bracket screws on both sides. 11. The left speaker has channels for Bluetooth, AirPort Extreme, inverter and the power cable from the DC-in board. Verify that the cables are routed and reconnected correctly. 12. Reconnect the DC-in board and Bluetooth flex cable to the logic board.

Display Panel Assembly 13. Verify that the LVDS cable’s bead fits into the metal channel and that the cable is secured into the channel along the right speaker. Then, reconnect the LVDS cable and verify that it does not go over the fan. 14. To verify that the pop-up mechanism was installed correctly, first make sure there are no wires or parts to interfere, then carefully close the display until it latches. Push the display latch button and the display should pop-up slightly. Note: If not, one or both limit stop feet, next to the clutch cleats, were not inserted correctly. Loosen the screws for the end caps and clutch cleats enough to push the feet into place and reinstall.

Display Panel Assembly 15. Reassemble and test the computer. 16. Testing the computer should include the display panel. Use Bluetooth to connect to another computer and verify proper AirPort Extreme function. Check the function of the DC-in port and the left USB port.

Heatsink and Fan Assembly Heatsink and Fan Assembly Tools This procedure requires the following tools: • Torx T8 screwdriver (magnetized) Part Location Preliminary Steps Before you begin, remove the following: • Battery • Top case • Left and right speakers • Logic board • Display panel assembly