Service Source PowerBook G4 (1GHz/867MHz) 5 December 2003 © 2003 Apple Computer, Inc. All rights reserved.
Service Source Take Apart PowerBook G4 (1GHz/867MHz) © 2002 Apple Computer, Inc. All rights reserved.
PowerBook G4 (1GHz/867MHz) Keyboard Replacement Instructions Follow the instructions in this sheet carefully. Failure to follow these instructions could damage your equipment and void its warranty. Note: Written and video instructions covering customer-installable parts are available at http://www.info.apple.com/installparts/. Warning: During this procedure, keep small parts away from children.
. Close the computer and turn it over. 5. Slide the battery latch (Figure 1A) to the right to remove the battery (Figure 1B). Removing the battery will prevent you from accidentally turning on the computer. Warning: Removing the battery before shutting down your computer may result in data loss. Figure 1 A B 6. Turn over the computer. 7. Raise the display so you can access the keyboard. 8.
9. Release the keyboard by pulling down on the keyboard release tabs (located to the left of the F1 and F12 keys) (Figure 3), then lift the top portion of the keyboard up slightly, and toward the display. Figure 3 ® 10. Flip the keyboard over and lay it on the palm rests and trackpad.
11. Touch the computer’s inside framework (a dull gray conductive composite material) to discharge any static electricity, as shown (Figure 5). Important: To avoid electrostatic discharge damage, always ground yourself by touching the computer’s framework before you touch any parts or install any components inside the computer. To avoid static electricity building back up in your body, do not walk around the room until you have completed your installation and closed the computer. Figure 5 12.
Installing the Replacement Keyboard 1. Lay the replacement keyboard in the correct orientation over the keyboard opening, then flip it toward you and lay it face down on the palm rests and trackpad to expose its connector cable. (Figure 7) Figure 7 2. Firmly insert the keyboard cable connector into its connector on the computer. 3. Flip the keyboard back toward the keyboard opening in the case. 4.
5. Lay the keyboard flat into the keyboard opening. 6. Pull down on the keyboard release tabs while pressing down on the top portion of the keyboard (Figure 9). Release the tabs to secure the keyboard in place. Figure 9 ® 7. Close the display and turn the PowerBook over. 8. Replace the battery. (Figure 10) Important: Make sure that the battery locks securely into place and that the battery latch is slid all the way into the locked position. Figure 10 9.
Apple Computer, Inc. © 2002 Apple Computer, Inc. All rights reserved. This document is protected under U.S. Copyright Law and International Treaties, and no part of this document may be reproduced in any form without written permission from Apple. Apple is not responsible for typographical, printing, or inadvertent errors. Apple Computer, Inc. 1 Infinite Loop Cupertino, CA 95014-2084 USA + 1 408 996 1010 http://www.apple.com Apple, the Apple logo, and PowerBook are trademarks of Apple Computer, Inc.
PowerBook G4 (1GHz/867MHz) Memory Card Replacement Instructions Follow the instructions in this sheet carefully. Failure to follow these instructions could damage your equipment and void its warranty. Note: Written and video instructions covering customer-installable parts are available at http://www.info.apple.com/installparts/. Warning: During this procedure, keep small parts away from children.
4. Close the computer and turn it over. 5. Slide the battery latch (Figure 1A) to the right to remove the battery (Figure 1B). Removing the battery will prevent you from accidentally turning on the computer. Warning: Removing the battery before shutting down your computer may result in data loss. Figure 1 A B 6. Turn over the computer. 7. Raise the display so you can access the keyboard. 8.
9. Release the keyboard by pulling down on the keyboard release tabs (located to the left of the F1 and F12 keys) (Figure 3), then lift the top portion of the keyboard up slightly, and toward the display. Figure 3 ® 10. Flip the keyboard over and lay it on the palm rests and trackpad.
11. Touch the computer’s inside framework (a dull gray conductive composite material) to discharge any static electricity, as shown (Figure 5). Important: To avoid electrostatic discharge damage, always ground yourself by touching the computer’s framework before you touch any parts or install any components inside the computer. To avoid static electricity building back up in your body, do not walk around the room until you have completed your installation and closed the computer.
Installing the Replacement Memory Card Warning: When handling a memory card, do not touch its gold connectors. Handle the card only by the edges. 1. To install the memory card, line up the notch in the card with the small tab in the memory slot. Hold the card at a 30-degree angle (Figure 7A), and then push the card into the slot until it is firmly seated. Note: You may feel some resistance. If you are having trouble inserting the card, try pushing one side at a time. Figure 7 A 2.
Closing the Computer 1. Flip the keyboard back toward the keyboard opening in the case. 2. Hold the keyboard at an angle and insert the tabs on the bottom edge of the keyboard into the slots below the edge of the keyboard opening. (Figure 9) Important: Make sure that all the tabs are seated and that the keyboard rests flush against the edge of the opening. Figure 9 3. Lay the keyboard flat into the keyboard opening. 4.
6. Replace the battery. (Figure 11) Important: Make sure that the battery locks securely into place and that the battery latch is slid all the way into the locked position. Figure 11 7. Reconnect the power cord and any other cables that were connected, and restart your computer. Warning: Never turn on your computer unless all of its internal and external parts are in place and it is closed. Operating the computer when it is open or missing parts can damage your computer or cause injury.
PowerBook G4 (1GHz/867MHz) Bottom Case Replacement Instructions Follow the instructions in this sheet carefully. Failure to follow these instructions could damage your equipment and void its warranty. Note: Written and video instructions covering customer-installable parts are available at http://www.info.apple.com/installparts/. Warning: Sharp edges can exist inside your computer and on any parts being removed or installed. Use caution to avoid injury.
4. Place a towel or soft cloth on a table in front of you. (Figure 1A) The towel or cloth will protect the keyboard and display area of the PowerBook when you flip it over to remove the battery and bottom case. Make sure it covers an area large enough for your PowerBook and that it hangs over the edge of the table. 5. With the display open at an angle greater than 90 degrees, carefully flip the PowerBook over and lay it flat, fully on the table.
7. Use a Torx T8 screwdriver to remove the seven bottom case screws in the order shown. (Figure 3) Important: To avoid damaging the case, be careful that the screwdriver tip does not slip out of the screw head during removal. Figure 3 1 3 2 4 7 6 5 Note: In the following two steps you will disengage the left and right sides of the bottom case and then pivot it forward to remove. 8. Carefully slide the bottom case away from you. (Figure 4) Important: Do not push on the rubber feet of the bottom case.
9. Pivot the bottom case up as shown. (Figure 5) Figure 5 Installing the Replacement Bottom Case 1. To attach the new bottom case, align the notches on the right and left sides of the case, then press down slightly to secure the case. Check the alignment of the seven screw holes to make sure the bottom case is properly positioned. Important: Make sure that the seams between the bottom case and the frame are closed. Check the outside edges and around the battery well.
3. Replace the battery. (Figure 7) Important: Make sure that the battery locks securely into place and that the battery latch is slid all the way into the locked position. Figure 7 4. Turn the computer over. Look at the optical drive slot to make sure that the case is properly secured. If a gap exists below the slot, gently pull the bottom of the optical drive slot toward you until it clicks into place and the gap is removed. (Figure 8) Figure 8 ® 5.
Apple Computer, Inc. © 2002 Apple Computer, Inc. All rights reserved. This document is protected under U.S. Copyright Law and International Treaties, and no part of this document may be reproduced in any form without written permission from Apple. Apple is not responsible for typographical, printing, or inadvertent errors. Apple Computer, Inc. 1 Infinite Loop Cupertino, CA 95014-2084 USA + 1 408 996 1010 http://www.apple.com Apple, the Apple logo, and PowerBook are trademarks of Apple Computer, Inc.
PowerBook G4 (1GHz/867MHz) AirPort Card Replacement Instructions Follow the instructions in this sheet carefully. Failure to follow these instructions could damage your equipment and void its warranty. Note: Written and video instructions covering customer-installable parts are available at http://www.info.apple.com/installparts/. Warning: Sharp edges can exist inside your computer and on any parts being removed or installed. Use caution to avoid injury.
4. Place a towel or soft cloth on a table in front of you. (Figure 1A) The towel or cloth will protect the keyboard and display area of the PowerBook when you flip it over to remove the battery and bottom case. Make sure it covers an area large enough for your PowerBook and that it hangs over the edge of the table. 5. With the display open at an angle greater than 90 degrees, carefully flip the PowerBook over and lay it flat, fully on the table.
7. Use a Torx T8 screwdriver to remove the seven bottom case screws in the order shown. (Figure 3) Important: To avoid damaging the case, be careful that the screwdriver tip does not slip out of the screw head during removal. Figure 3 1 3 2 4 7 6 5 Note: In the following two steps you will disengage the left and right sides of the bottom case and then pivot it forward to remove. 8. Carefully slide the bottom case away from you. (Figure 4) Important: Do not push on the rubber feet of the bottom case.
9. Pivot the bottom case up as shown. (Figure 5) Figure 5 10. Touch the computer’s inside framework (a dull gray conductive composite material) to discharge any static electricity, as shown. (Figure 6) Important: To avoid electrostatic discharge damage, always ground yourself by touching the computer’s framework before you touch any parts or install any components inside the computer.
Removing the Installed AirPort Card 1. Pull back on the antenna clip (Figure 7A) to release the antenna cable connector (Figure 7B) and allow the card to rise up slightly. 2. Pull the card from the AirPort connector (Figure 7D). 3. If there is tape securing the antenna cable to the AirPort Card, carefully remove it and store it in the battery compartment for reuse later. When installing the replacement AirPort Card, use the tape to secure the cable in the same manner. 4.
Installing the Replacement AirPort Card 1. If the replacement AirPort Card came with the AirPort adapter (Figure 8A), remove the metal clip (Figure 8B) and pull the AirPort Card (Figure 8C) from the adapter. (The adapter and metal clip are not used with your PowerBook.) Figure 8 A C B 2. If necessary, pull the AirPort antenna cable connector (Figure 9A) from its holder (Figure 9B). Figure 9 B A 3. Position the AirPort Card (Figure 10B) with the AirPort ID numbers and bar code facing up.
4. Plug the antenna cable connector (Figure 11A) into the port on the AirPort Card, located just below the plastic tab (Figure 11B). Make sure the connector is straight before inserting it into the port. Note: If tape was removed earlier, use it to secure the antenna cable to the card. 5. Push the AirPort Card down until the antenna cable connector is secured by the small antenna clip (Figure 11C). Important: Route the antenna cable (Figure 11D) between the edge of the computer and the AirPort Card.
Closing the Computer 1. To attach the bottom case, align the notches on the right and left sides of the case, then press down slightly to secure the case. Check the alignment of the seven screw holes to make sure the bottom case is properly positioned. Important: Make sure that the seams between the bottom case and the frame are closed. Check the outside edges and around the battery well. Verify that the alignment tab on the underside of the bottom case (Figure 12A) has seated, and the case lies flat. 2.
3. Replace the battery. (Figure 13) Important: Make sure that the battery locks securely into place and that the battery latch is slid all the way into the locked position. Figure 13 4. Turn the computer over. Look at the optical drive slot to make sure that the case is properly secured. If a gap exists below the slot, gently pull the bottom of the optical drive slot toward you until it clicks into place and the gap is removed. (Figure 14) Figure 14 ® 5.
Apple Computer, Inc. © 2002 Apple Computer, Inc. All rights reserved. This document is protected under U.S. Copyright Law and International Treaties, and no part of this document may be reproduced in any form without written permission from Apple. Apple is not responsible for typographical, printing, or inadvertent errors. Apple Computer, Inc. 1 Infinite Loop Cupertino, CA 95014-2084 USA + 1 408 996 1010 http://www.apple.com Apple, the Apple logo, and PowerBook are trademarks of Apple Computer, Inc.
PowerBook G4 (1GHz/867MHz) Hard Drive Replacement Instructions Follow the instructions in this sheet carefully. Failure to follow these instructions could damage your equipment and void its warranty. Note: Written and video instructions covering customer-installable parts are available at http://www.info.apple.com/installparts/. Warning: Sharp edges can exist inside your computer and on any parts being removed or installed. Use caution to avoid injury.
4. Place a towel or soft cloth on a table in front of you. (Figure 1A) The towel or cloth will protect the keyboard and display area of the PowerBook when you flip it over to remove the battery and bottom case. Make sure it covers an area large enough for your PowerBook and that it hangs over the edge of the table. 5. With the display open at an angle greater than 90 degrees, carefully flip the PowerBook over and lay it flat, fully on the table.
7. Use a Torx T8 screwdriver to remove the seven bottom case screws in the order shown. (Figure 3) Important: To avoid damaging the case, be careful that the screwdriver tip does not slip out of the screw head during removal. Figure 3 1 3 2 4 7 6 5 Note: In the following two steps you will disengage the left and right sides of the bottom case and then pivot it forward to remove. 8. Carefully slide the bottom case away from you. (Figure 4) Important: Do not push on the rubber feet of the bottom case.
9. Pivot the bottom case up as shown. (Figure 5) Figure 5 10. Touch the computer’s inside framework (a dull gray conductive composite material) to discharge any static electricity, as shown. (Figure 6) Important: To avoid electrostatic discharge damage, always ground yourself by touching the computer’s framework before you touch any parts or install any components inside the computer.
Removing the Installed Hard Drive 1. With your fingers, carefully pry up the hard drive cable connector (Figure 7A) at its sides to disconnect it from the logic board. You may need to pry one side, then the other, in a rocking motion. Figure 7 A 2. With a Torx T8 screwdriver, remove the two screws that secure the hard drive mounting bracket, and remove the bracket.
3. Pull up on the right side of the hard drive to remove it. (Figure 9) Important: The hard drive connector cable can be carefully used to help remove the hard drive if it lifts easily. Do not pull hard on the connector cable. Figure 9 Note: There are four rubber stoppers on the hard drive that fit over screws (two on each side). Remove any that may have fallen off or that remain in the holes in the mounting bracket inside the computer. 4.
Installing the Replacement Hard Drive Warning: To avoid potential injury or damage, avoid touching the thin strip of metal that extends up from the rib frame at the battery well. Important: Avoid touching the optical drive as you perform this procedure. 1. Make sure that the screws (Figure 10A) and rubber stoppers (Figure 10B) are in place on the sides of the replacement drive. 2. Install the Mylar sheath (Figure 10C) so that it covers the bottom and left and right sides of the drive.
5. Replace the hard drive mounting bracket and secure with the screws. (Figure 12) Important: Check that the rubber stoppers and Mylar sheath are not pinched by the bracket. Figure 12 6. Connect the hard drive cable connector (Figure 13) to the logic board.
Closing the Computer 1. To attach the bottom case, align the notches on the right and left sides of the case, then press down slightly to secure the case. Check the alignment of the seven screw holes to make sure the bottom case is properly positioned. Important: Make sure that the seams between the bottom case and the frame are closed. Check the outside edges and around the battery well. Verify that the alignment tab on the underside of the bottom case (Figure 14A) has seated, and the case lies flat. 2.
3. Replace the battery. (Figure 15) Important: Make sure that the battery locks securely into place and that the battery latch is slid all the way into the locked position. Figure 15 4. Turn the computer over. Look at the optical drive slot to make sure that the case is properly secured. If a gap exists below the slot, gently pull the bottom of the optical drive slot toward you until it clicks into place and the gap is removed.
5. Reconnect the power cord and any other cables that were connected, and restart your computer. Warning: Never turn on your computer unless all of its internal and external parts are in place and it is closed. Operating the computer when it is open or missing parts can damage your computer or cause injury. 6. Restore the data from your backup to the new drive. 7. Check the operation of the optical drive.
PowerBook G4 (1GHz/867MHz) Modem Filter Board Replacement Instructions The following instructions explain how to replace the modem EMI filter board in the PowerBook G4 (1GHz/867MHz) computer. Tools • Black stick (nylon probe tool 922-5065) or other ESD-safe, non-marring tool • Torx T8 screwdriver Preliminary Steps Before you begin, remove the following: • Battery • Keyboard © 2002 Apple Computer, Inc. All rights reserved.
Procedure 1. Disconnect the RJ-11 and the modem wire connectors from the modem filter board. 2. Remove the Torx T8 screw. 3. Guide the modem filter board out of the case.
PowerBook G4 (1GHz/867MHz) DC-In Board Replacement Instructions The following instructions explain how to replace the DC-in board in the PowerBook G4 (1GHz/867MHz) computer. Tools • Black stick (nylon probe tool 922-5065) or other ESD-safe, non-marring tool • Torx T6 screwdriver Preliminary Steps Before you begin, remove the following: • Battery • Bottom case © 2002 Apple Computer, Inc. All rights reserved.
Procedure 1. Disconnect the DC-in board cable connector from the logic board. 2. Remove the two Torx T6 screws. Note: The screw holding the fan securing tab may be longer than the other. 3. Guide the DC-in board out of the case.
Replacement Note: If you performed a procedure that also removed the logic board, ensure that the power button cable routes up and left, toward the center of the top case, under the DC-in board. Replacement Notes: • Install the 1 mm plastic screw shim to the replacement DC-In board.
• When replacing the DC-in board, ensure that the secondary fan is seated properly over the pin on the rib frame, and with its securing-tab resting on top of the DC-In board. If one screw was longer, replace it through the fan’s securing-tab. • Make sure that the DC connector is straight and centered in the port opening. With the power adapter unplugged, the adapter connector may be inserted onto the DC connector to ensure that the connector is centered and straight before securing the DC-in board.
PowerBook G4 (1GHz/867MHz) Inverter Board Replacement Instructions The following instructions explain how to replace the inverter board in the PowerBook G4 (1GHz/867MHz) computer. Tools • Black stick (nylon probe tool 922-5065) or other ESD-safe, non-marring tool • Torx T6 screwdriver Preliminary Steps Before you begin, remove the following: • Battery • Bottom case © 2002 Apple Computer, Inc. All rights reserved.
Procedure Important: With the bottom case removed, be careful if turning over the computer. Some components could become loose and fall out. 1. Disconnect the inverter board flex cable from both the inverter board and logic board. 2. Disconnect the bulb wire cable from the inverter board. 3. Remove the two T6 screws that secure the inverter board and remove the board.
4. Install the replacement inverter board onto the optical drive. 5. Reassemble and test the computer. Important: Make sure the bottom case is installed correctly. If the slot-load area is slightly bowed, carefully pull the bottom edge of the slot until it clicks into place and becomes flush with the bottom case. Important: Check the operation of the optical drive.
PowerBook G4 (1GHz/867MHz) Modem Replacement Instructions The following instructions explain how to replace the modem in the PowerBook G4 (1GHz/ 867MHz) computer. Tools • Black stick (nylon probe tool 922-5065) or other ESD-safe, non-marring tool • Torx T6 screwdriver • Torx T8 screwdriver Preliminary Steps Before you begin, remove the following: • Battery • Keyboard • Bottom case (remove in step 2) © 2002 Apple Computer, Inc. All rights reserved.
Procedure 1. With the display open and the keyboard removed, locate and remove the EMI clip that secures the optical drive’s flex cable to the rib frame. Side until reassembling the computer. Replacement Note: When reassembling the computer, ensure that the EMI clip captures the tab on the flex cable and holds it against the rib frame. 2. Remove the bottom case. Important: With the bottom case removed, be careful if turning over the computer. Some components could become loose and fall out. 3.
4. Disconnect the inverter board flex cable from the inverter board and logic board. 5. Disconnect the optical drive and modem flex cables from the logic board. 6. Remove the two T6 screws that secure the modem. 7. Lift up the end of the modem slightly and disconnect the 2-pin cable connector.
8. Use a thin tool to lift the optical drive slightly, then deroute the modem flex cable. 9. If the modem flex cable is not damaged, remove it and transfer it to the replacement modem. 10. Install the replacement modem. Avoid putting pressure on or stressing the modem board during installation. 11. To replace the optical drive, carefully guide the rubber stoppers on the outer side of the drive past the edge of the computer case.
12. Reassemble and test the computer. Replacement Note: When reinstalling the optical drive, ensure that the bulb wire cable is safely within the case edge so that it will not get pinched by the bottom case. Important: Make sure the bottom case is installed correctly. If the slot-load area is slightly bowed, carefully pull the bottom edge of the slot until it clicks into place and becomes flush with the bottom case. Important: Check the operation of the optical drive.
PowerBook G4 (1GHz/867MHz) DVD-ROM/CD-RW (Combo), DVD-R/CD-RW (Apple SuperDrive) Optical Drive Replacement Instructions The following instructions explain how to replace the combination DVD-ROM/CD-RW optical drive in the PowerBook G4 (1GHz/867MHz) computer.
Procedure 1. With the display open and the keyboard removed, locate and remove the EMI clip that secures the optical drive’s flex cable to the rib frame. Set it aside for installation of the replacement drive. Replacement Note: When installing the replacement drive, ensure that the EMI clip captures the tab on the flex cable and holds it against the rib frame. 2. Remove the bottom case. Important: With the bottom case removed, be careful if turning over the computer.
3. Remove the two T8 screws that secure the hard drive mounting bracket and remove the bracket. 4. Disconnect the inverter board flex cable from the inverter board and logic board. 5. Disconnect the optical drive and modem flex cables from the logic board.
6. Disconnect the bulb wire cable from the inverter board. 7. Remove the four T6 screws that secure the modem and the inverter board and remove the inverter board. Replacement Note: When reinstalling the replacement optical drive, ensure that the bulb wire cable is safely within the case edge so that it will not get pinched by the bottom case. 8. Lift up the end of the modem slightly and disconnect the 2-pin cable connector.
9. Use a thin tool to lift the optical drive slightly, then deroute the modem flex cable. 10. Warning: To prevent damage to the optical drive, handle the drive only by the corners. Do not press on the body of the drive. To remove the optical drive, pull the drive to the right, away from the hard drive, to release the long rubber stopper from the rib frame. 11.
Peel off the felt strip from the inner top case. If there is any residual adhesive on the top case, rub it away. Apply the new felt strip to the slot-load area. Make sure the new felt strip lies flat. Use a black stick to run the length of the slot to make sure that the felt strip does not block any of the slot. 12. Install the modem and inverter board onto the replacement optical drive. Again, handle the optical drive only by the corners. Do not press on the body of the drive. 13.
14. Reassemble and test the computer. Important: Make sure the bottom case is installed correctly. If the slot-load area is slightly bowed, carefully pull the bottom edge of the slot until it clicks into place and becomes flush with the bottom case. Important: Check the operation of the optical drive. If the drive is installed incorrectly, the optical drive mechanism might not spin correctly and will result in mechanical noise when playing a disc.
PowerBook G4 (1GHz/867MHz) Backup Battery Replacement Instructions The following instructions explain how to replace the backup battery in the PowerBook G4 (1GHz/867MHz) computer. Tools • Black stick (nylon probe tool 922-5065) or other ESD-safe, non-marring tool Preliminary Steps Before you begin, remove the following: • Battery • Optical drive © 2002 Apple Computer, Inc. All rights reserved.
Procedure 1. Disconnect the backup battery cable from the backup battery. Note: If the cable connector gets caught on the ridged area of the top case, use a black stick to raise up the backup battery and then disconnect the cable. 2. Note: The backup battery is compressed between two thin plastic sheets. The battery is held in place with adhesive on the lower plastic sheet. Slide a black stick under and along the edge of the backup battery.
3. If there is any adhesive left on the surface of the inner top case, use a black stick to rub it away. Do not use solvents. Note: When installing the replacement backup battery, make sure the inner top case is clean and free of debris. 4. Peel off the cover sheet from the bottom surface of the replacement backup battery to expose the adhesive. 5. When positioning the replacement backup battery on the inner top case, make sure the battery fits within the ridged battery area of the inner top case. 6.
PowerBook G4 (1GHz/867MHz) Logic Board Replacement Instructions The following instructions explain how to replace the logic board in the PowerBook G4 (1GHz/867MHz) computer. Tools • • • • • Torx T8 screwdriver Black stick (nylon probe tool 922-5065) or other ESD-safe, non-marring tool Razor blade Needle nose pliers (optional) Medium tip permanent black ink marker Note: To organize the screws you remove from the computer, use a tray with divided compartments (such as a plastic ice cube tray).
Procedure 1. With the display open and the keyboard removed, remove the T8 screw near the heat pipe. 2. Disconnect the PC card flex cable connector and the keyed battery connector. Important: If the battery connector has not been disconnected before, the keyed connector may be tight. If necessary, use a black stick or needle nose pliers to loosen one side of the connector and then the other side. Then insert the black stick under the cables to pry up and disconnect the connector.
3. Disconnect the 3-pin backup battery connector from the logic board. 4. Remove the items listed in Preliminary Steps, to be removed in step 4. Important: With the bottom case removed, be careful when turning over the computer. Some components could become loose and fall out.
5. Warning: The thin cables connected to the LVDS (low voltage data signal) connector are extremely delicate. Do not pull or pinch the LVDS cables. Be especially careful when working near cables that attach to the display. If any of these cables are damaged, the entire display module must be replaced. At the left side of the logic board, disconnect the 2-pin sleep LED cable connector, the LVDS connector, and the 6-pin audio connector.
6. At the right side of the logic board, disconnect the 2-pin power button cable connector, the DC-in board cable connector, and the inverter board and modem flex cable connectors. 7. Disconnect the trackpad, hard drive and optical drive flex cable connectors. Note: If tape is covering the trackpad connector, reserve the tape for installation of the replacement logic board.
8. Remove the T8 screw on the edge of the logic board near the battery well. Important: Install this screw first when installing the replacement logic board. This screw helps the logic board align properly to the rib frame. 9. Remove the T8 screw securing the PC card cage.
10. Remove the five identical (bronze colored) T8 screws. Note: When reassembling the computer, do not overtighten the screws.
11. Grasp the logic board near the AirPort Card carrier and gently lift the board up, as shown below, being careful where it catches on ports, back panel mesh liner, and disconnected cables. If necessary, open the panel door and press on the ports to free the logic board from the back panel. Important: Lift the board just enough to access and disconnect the secondary fan’s connector on the logic board before removing the board.
12. Remove existing memory cards from the logic board for installation on the replacement logic board. Carefully spread the end brackets to allow the card to raise up, then pull out.
13.
14.
• Rectangular plastic standoffs around the chips on the underside of the replacement logic board. Note: If openings are present in the standoffs, position them where shown by circles, below. Important: If transfering from the old board, use a razor knife to remove and be very careful not to damage board components.
• Plastic 1 mm and 1.5 mm washers around the screw holes, shown. Center and press into place.
15. Check that the heat exchanger has three rectangular thermal interface pads in place. If the pads are missing or damaged, replace the heat exchanger. 16. Use a razor blade or black stick to gently scrape away any residual thermal transfer material on the heat exchanger on the surface that mates with the microprocessor.
17. Important: If you have removed the logic board to access another part, and you will be placing the original logic board back in the computer, use a black stick to gently scrape away any residual thermal transfer material from the microprocessor chip on the logic board. Warning: When scraping away the thermal transfer material from the microprocessor chip, be careful not to nick the microprocessor chip. 18.
19. Remove the new Ethernet label from the area inside the memory card brackets, peel off the adhesive protector and attach the label, right side up, over the Ethernet ID and bar code on the ID plate inside the battery well.
20. Install the replacement logic board, and reassemble the computer. Replacement Note: When replacing the logic board, the RJ-11 cable and backup battery wire connectors must be routed, as shown below, so that they do not interfere with the logic board replacement and can later be accessed through the keyboard opening. Ensure that optical drive’s flex cable has not been pulled out of the EMI clip, and that the clip still secures the tab on the flex cable to the rib frame. 21.
PowerBook G4 (1GHz/867MHz) Primary Fan Replacement Instructions The following instructions explain how to replace the primary fan in the PowerBook G4 (1GHz/867MHz) computer. Tools • Black stick (nylon probe tool 922-5065) or other ESD-safe, non-marring tool • Razor blade • Needle nose pliers Preliminary Steps Before you begin, remove the following: • Battery • Logic Board © 2002 Apple Computer, Inc. All rights reserved.
Procedure 1. With the logic board removed from the computer, disconnect the fan connector from the logic board. 2. Turn over the logic board, and locate the cone-shaped pin at the right corner of the fan. Pull the rubber pin tight. Use a razor blade to cut through the rubber pin.
3. Turn over the logic board, then tilt up the fan to remove it completely from the logic board. Note: The fan is secured to the logic board by adhesive. Rub off any remaining adhesive from the logic board. Do not use solvents. Replacement Procedure 1. When installing the replacement fan, if the rubber pin is not installed in the fan, insert the long end of the pin into the hole at the top of the fan and pull the middle cone through and out so that the flat end remains on the top of the fan.
PowerBook G4 (1GHz/867MHz) Secondary Fan Replacement Instructions The following instructions explain how to replace the secondary fan in the PowerBook G4 (1GHz/867MHz) computer. Tools • Black stick (nylon probe tool 922-5065) or other ESD-safe, non-marring tool • Torx T6 screwdriver Preliminary Steps Before you begin, remove the following: • Battery • Logic Board (disconnect the fan’s connector from the logic board while removing the logic board) © 2002 Apple Computer, Inc. All rights reserved.
Procedure 1. Remove the T6 screw from the fan bracket. 2. Disconnect the fan’s connector from the logic board while removing the logic board. Lift out the fan assembly.
PowerBook G4 (1GHz/867MHz) PC Card Cage Replacement Instructions The following instructions explain how to replace the PC card cage in the PowerBook G4 (1GHz/867MHz) computer. Tools • Torx T8 screwdriver • 4 mm Hex socket or wrench • 5 mm Hex socket or wrench Preliminary Steps Before you begin, remove the following: • Battery • Keyboard • Logic board © 2002 Apple Computer, Inc. All rights reserved.
Procedure 1. Remove the two screws that attach the PC card cage to the rib frame. (The longer screw is next to the battery connector.) 2. To remove the 4 mm hex nut that secures the PC card cage to the heat exchanger, you may want to use a finger to support the 5 mm (magnetic) hex screw underneath the nut to prevent the screw from falling out of the screw hole. Loosen and remove the hex nut. Remove the PC card cage, being careful where it can catch on the PC card eject button.
3. Check that the replacement PC card cage includes a clear plastic shim on the outer frame near the PC card eject button. If the shim is not there, transfer the shim from the old PC card cage to the replacement PC card cage. 4. When installing the replacement PC card cage, ensure that the metal flange that is closest to the PC card eject button goes underneath the rib frame and metal liner at the battery latch. 5. Install the replacement PC card cage, and reassemble and test the computer.
PowerBook G4 (1GHz/867MHz) Rib Frame and Heat Exchanger Replacement Instructions The following instructions explain how to replace the rib frame and the heat exchanger in the PowerBook G4 (1GHz/867MHz) computer. Warning: Make sure you carefully follow these instructions, especially when working near cables that attach to the display module. If any of the cables are damaged, the entire display module must be replaced.
Procedure 1. With the display open and the keyboard removed, remove the five identical T8 screws from the top case. 2. Remove the items listed in Preliminary Steps, to be removed in step 2. Important: With the bottom case removed, be careful when turning over the computer. Some components could become loose and fall out. 3. Open the I/O door, and remove the four identical T6 screws. 4. Lift out the two back panel mounts from the notches in the rib frame.
5. Close the computer to an approximate 45-degree angle, and stand it on a soft cloth with the clutch covers facing up. 6. Remove the four identical T8 screws from the clutch covers (two screws on each clutch cover). 7. Use a black stick to pry off the two clutch covers. Note: Opening the display slightly may help to remove the covers.
8. Open the computer so that the display rests in your lap and is protected by a soft cloth. 9. Warning: Be especially careful when working near cables that attach to the display. If any of these cables are damaged, the entire display module must be replaced. Warning: At the left clutch, the wrapped cable connected to the LVDS (low voltage data signal) connector is extremely delicate. Do not pull or pinch the LVDS cable. Do not allow the screwdriver to touch the LVDS cable.
10. At the right clutch, note the routing of the inverter cable. Without straining the inverter cable, gently move it aside so you can access the two large silver-colored screws. 11. Support the display as you remove the two identical, large, silver-colored T8 screws from the right clutch. (Do not remove the smaller screws.) 12. Important: With the display hinge disconnected, support the display as you place it face-down on a soft cloth in front of the computer chassis.
13. Remove the four rib frame screws. Three are identical black T8 screws, the forth is a longer chrome T8 and also secures the heat exchanger alignment bracket to the end of the heat exchanger. (You might need to move aside the AirPort antenna cable to reach one of the screws.) Replacement Note: Make sure to replace the longer chrome screw through the alignment bracket so that it secures the small alignment nub on the end of the heat exchanger.
15. Disconnect the audio cable at each end of the heat exchanger.
16. Pivot the heat exchanger out of the top case assembly. Be careful where it might catch at the LVDS cable. Warning: At the left clutch, the wrapped cable connected to the LVDS connector is extremely delicate. Do not pull or pinch the LVDS cable. Warning: Do not bend the heat pipe.
17. If replacing the rib frame but reusing the heat exchanger, scrape off the thermal transfer material residue from the area shown. Apply new thermal transfer material to the logic board chip. Replacement Notes: If replacing the heat exchanger, transfer the hex nut and screw to the replacement heat exchanger. When replacing the heat exchanger, check that the audio cable is routed as shown. If replacing the rib frame, transfer the battery connector to the replacement rib frame, if needed.
PowerBook G4 (1GHz/867MHz) Bulb Wire Cable Replacement Instructions The following instructions explain how to replace the bulb wire cable in the PowerBook G4 (1GHz/867MHz) computer. Tools • Black stick (nylon probe tool 922-5065) or other ESD-safe, non-marring tool • Torx T8 screwdriver Preliminary Steps Before you begin, remove the following: • Battery • Optical drive • Logic board © 2002 Apple Computer, Inc. All rights reserved.
Procedure Important: With the bottom case removed, be careful if turning over the computer. Some components could become loose and fall out. Note: Remove any kapton tape as needed and replace during reassembly. 1. Loosen or remove the chrome T8 screw holding the heat exchanger alignment bracket and the right side of the rib frame. 2. Disconnect the bulb wire cable connector. Replacement Note: Make sure the alignment bracket secures the small alignment nub on the end of the heat exchanger.
Replacement Note: After reconnecting the bulb wire, ensure that the bulb wire cable is safely tucked within the case edge so that it will not get pinched by the bottom case. 4. Reassemble and test the computer. Important: Make sure the bottom case is installed correctly. If the slot-load area is slightly bowed, carefully pull the bottom edge of the slot until it clicks into place and becomes flush with the bottom case. Important: Check the operation of the optical drive.
PowerBook G4 (1GHz/867MHz) I/O Door Replacement Instructions The following instructions explain how to replace the I/O door in the PowerBook G4 (1GHz/867MHz) computer. Tools • Black stick (nylon probe tool 922-5065) or other ESD-safe, non-marring tool • Needle nose pliers Preliminary Steps Before you begin, remove the following: • Battery • Logic board © 2002 Apple Computer, Inc. All rights reserved.
Procedure 1. Using needle nose pliers, pull off the rubber plugs at each end of the door. Remove the springs, and set aside the plugs and springs. Important: Be very careful not to damage or bend the heat exchanger pipes. 2. Pull the door away from the top case. 3. Remove the L-shaped pin from each end of the I/O door. Note: The L-shaped pin has a knob at one end. The knobbed end holds the rubber plug onto the L-shaped pin. 4. Install the replacement I/O door.
PowerBook G4 (1GHz/867MHz) Display Module Replacement Instructions The following instructions explain how to replace the display module on the PowerBook G4 (1GHz/867MHz) computer. Warning: Make sure you carefully follow these instructions, especially when working near cables that attach to the replacement display module. If any of the cables are damaged, the entire display module must be replaced.
Procedure 1. With the rib frame and heat exchanger removed, make sure • The display is supported on a soft cloth in front of the top case • The display cables are not strained Warning: Be especially careful when working near cables that attach to the display. If any of these cables are damaged, the entire display module must be replaced. The LVDS cable and connector are extremely delicate. Do not pull or pinch the LVDS cable or connector.
3. Thread the 2-pin LED sleep cable through the opening in the top case. Carefully guide the LVDS cable through the opening by looping the cable and turning the LVDS connector sideways, as shown, to fit through the opening. 4. At the right clutch, raise the inner clutch mount and disconnect the inverter cable. Carefully slide the inverter cable out through the opening in the top case. 5. The display module includes all three cables.
6. Important: When the replacement display module is installed, and before the clutch covers are installed, test that the display is seated properly. With the computer upright and closed, press the computer latch. The display module should pop up slightly if the module is properly seated. 7. Install the replacement display module, and reassemble and test the computer.
PowerBook G4 (1GHz/867MHz) Top Case Replacement Instructions The following instructions explain how to replace the top case in the PowerBook G4 (1GHz/867MHz) computer. Tools • Black stick (nylon probe tool 922-5065) or other ESD-safe, non-marring tool • Razor blade (optional) Preliminary Steps Before you begin, remove the following: • Battery • Backup battery • Display module • I/O door © 2002 Apple Computer, Inc. All rights reserved.
Procedure 1. With the preliminary steps completed, compare the original top case to the replacement top case. 2. Before installing the replacement top case, make sure it includes the following: • Speaker set and cables • Power button and board (heatstaked to top case) • AirPort antenna cable • Trackpad assembly with board and cable 3. Important: Make sure you transfer the original serial number label from the old top case to the serial number panel on the replacement top case.
4. Confirm that the thermal strip and mesh liners are installed at the back panel. 5. Important: Make sure you transfer the backup battery cable from the original top case to the replacement top case. The backup battery cable is tucked below the bulb wire cable along and between the speaker and top case, as shown. 6. Install the replacement top case, and reassemble and test the computer.
Service Source Troubleshooting PowerBook G4 (1GHz/867MHz) © 2002 Apple Computer, Inc. All rights reserved.
Symptom Charts How to Use the Symptom Charts The Symptom Charts included in this chapter will help you diagnose specific symptoms related to the product. The steps to solve a symptom are listed sequentially. You might not need to perform every step before the symptom is solved. Start with the first step, and then test for the symptom. If the symptom persists, replace any modules you removed, go to the next step, and test again. Continue down the list until the symptom is solved.
6. With a non-metallic tool, reset the power manager by pressing the reset button (located under the keyboard in the recess just left of the power button). Wait five seconds before continuing. Press the power button to start the computer. Warning: Resetting the power manager will permanently remove a RAM disk, if present, and all of its contents. You will also need to reset the date and time (using the Date & Time control panel) . 7.
Flashing question mark appears on the screen 1. Start up from the software install and restore disc that came with the computer (hold down the "C" key during restart). 2. When the Installer opens, from the Installer menu, select Open Disk Utility. 3. If the hard drive is recognized, under the First Aid tab verify the hard disk, and repair if needed. Restart the computer. 4. If the hard drive is not recognized, reseat the hard drive flex cable. If still not recognized, replace the hard drive. 5.
4. Make sure system is not over heating, the air vents are clear and unit is not on soft surface. 5. Check that the fan cable is connected and the fan is operational. 6. Check that the heat exchanger is properly attached to the processor. Important: If the heat exchanger is separated from the logic board, new thermal transfer material for the processor must be reinstalled. 7.
At startup, a dialog box comes up stating: “kernel panic” in Mac OS X or “Built-in memory test has detected an error” in Mac OS 9 1. If there are two RAM cards installed in the expansion slots, remove top card and restart. • If symptom repeats, replace bottom card with known-good RAM card. • If symptom does not repeat, replace top RAM card with known-good RAM card and restart.
3. If a RAM card is not installed in the upper expansion slot, replace RAM in lower RAM slot with known-good and compatible RAM card and restart. • If symptom repeats, replace logic board. Computer beeps four times at startup 1. Four beeps indicates a bad checksum for the remainder of the boot ROM. The ROM (which is located on the logic board) is bad. 2. Replace RAM card(s) with known-good and compatible RAM and restart. • If symptom repeats, replace logic board.
The battery won't charge 1. Remove any externally connected peripherals. 2. Try known-good power outlet. 3. Connect known-good PowerBook (1GHz/867MHz) power adapter (661-1798) and power cord or plug; make sure the DC plug is firmly inserted. The DC plug should light up, if not, replace DC-in board. If the power adapter light is green, turn over the computer and press the battery button. The battery lights should glow green and stay on if the power adapter is operating correctly.
Display Display latch not working Note: When the display is being closed, a latch hook in the top of the display housing should be magnetically pulled down through the slot in the top case and secured by the latch mechanism. When the latch button is pushed, the hook should release and retract into the display housing. 1. See the Latch Adjustment chapter in the Adjustments section of this service manual to verify the latch mechanism and latch hook operation and make adjustments, if necessary. 2.
5. If the number of subpixel anomalies is acceptable, explain to the customer that the pixel anomalies are within specifications, and no repair is necessary. Important: Do not release the specifications to customers. Instead, inform them that a certain number of subpixel anomalies are considered acceptable, and these factors apply to all manufacturers using LCD technology—not just Apple products.
Hard Drive Internal hard drive will not initialize If in Mac OS X: 1. Start up from the software install and restore disc that came with the computer (hold down the "C" key during restart). 2. When the Installer opens, from the Installer menu, select Open Disk Utility. 3. If the hard drive is recognized, format it under the Erase tab. 4. If the hard drive is not recognized, reseat or replace if needed, the hard drive flex cable. 5. If still not recognized, replace the hard drive. 6.
Modem No modem dial tone 1. Check that the correct modem is selected. In Mac OS X, check Network Setup. In Mac OS 9, check the Modem control panel. 2. Verify known-good analog (not digital) telephone line. 3. Verify known-good RJ11 telephone cable. 4. Verify RJ11 cable is not plugged into Ethernet port. 5. Inspect RJ11 connector and modem port for pin damage. 6. Verify RJ11 telephone cable is firmly installed in the modem port. 7.
The disc icon does not show up on desktop, or a dialog box appears to initialize disc, when inserting a read-only disc 1. Verify the correct type of disc is being used. 2. Note: Some brands of 24x or 32x CD-R media may not work with the SuperDrive. Try a different brand or speed of CD-R disc. 3. Use Software Update control panel to update firmware. 4. Try cleaning the disc. If it is dirty or scratched, it may not mount. 5. Try a different disc. 6.
Ports The FireWire or USB port is not recognizing devices 1. Completely shut down, then press the power button to start the computer. 2. Use Software Update in Mac OS X system preferences (or the Software Update control panel in Mac OS 9) to verify that the latest software is installed. 3. Use Apple System Profiler to verify that the computer is recognizing the bus. 4. For USB, test ports with an Apple keyboard or mouse. 5. For FireWire, test by connecting another computer in FireWire Target Disk Mode.
Sound No sound heard and the Speakers section of the Sound control panel indicates that an external device is plugged in (to the headphone jack or USB ports) 1. If there is nothing plugged into the headphone jack or USB ports, the picture in the Speakers section of the Sound control panel should be of the internal speakers, as shown here. 2. If not, and if nothing is plugged in, try plugging in headphones or external speakers. Restart the computer. Remove the device. 3.
7. Reset PRAM (Press the power button, then hold down the Option-Command-P-R keys until you hear the startup chime at least one additional time after the initial startup chime). Warning: Resetting the PRAM will permanently remove a RAM disk, if present, and all of its contents. You will also need to reset the date and time (using the Date & Time control panel). 8. Verify that the speaker cable is connected properly to logic board. 9. Check speaker cable. Verify left and right cable connections. 10.
7. Replace inverter board. 8. Replace display assembly. 9. Replace logic board. Computer appears to work, but no video on external device connected to the TV out port (S-video out port) 1. The device must be connected to the S-video port while the PowerBook is sleeping or off for the device to be recognized. 2. If running Mac OS X, verify that this issue is also in Mac OS 9. 3. Verify monitor that is used in testing is known-good and is supported by this computer. 4. Try different cable(s). 5.
The Date and Time settings reset all the time Note: Resetting the power manager or PRAM resets the date and time. 1. Do a backup battery test: • Set the date and time. • Perform a Shut Down from the Apple menu or Special menu. • Remove the main battery and disconnect the power adapter for 10 minutes. • Connect the power adapter, insert the battery, and power on the computer. • If the date and time were lost the backup battery may be dead or discharged.
5. If no sound as well as microphone is not working, verify cable connections. 6. Replace top case. During startup boot sequence and before reaching Finder, the following dialog box appears: “The built-in memory test has detected an error” 1. If a RAM card is installed in the upper expansion slot (if not, skip to next step), remove it and restart. Refer to Memory Card Replacement instructions. • If symptom does not repeat, replace RAM card.
PowerBook G4 (1GHz/867MHz) Screw Reference Sheet This sheet shows the screws used in the PowerBook G4 (1GHz/867MHz) computer and indicates the replacement procedure where first removed. To see where the screws are located in the computer, refer to the "PowerBook G4 (1GHz/867MHz) Screw Locator." Torx T6, 4.15 mm long: DC-In Board (1) Inverter Board (2) Modem (2) Torx T6, 5.12 mm long: DC-In Board (1) Secondary Fan (DC-In Board) (1) Torx T8, 4.4 mm long: Rib Frame and Heat Exchanger (5) Torx T8, 4.
PowerBook G4 (1GHz/867MHz) Screw Locator Bottom Case Seven identical Torx T8, 8 mm long Hard Drive and Optical Drive Hold Down Bracket Two identical Torx T8, 9.3 mm long Hard Drive Four identical (black) Torx T8, 4.9 mm long Modem Filter Board One Torx T8, 4.5 mm long © 2002 Apple Computer, Inc. All rights reserved.
Secondary Fan One Torx T6, 5.12 mm long DC-In Board 269 A One Torx T6, 4.15 mm long (A) - One Torx T6, 5.12 mm long Inverter Board Two Torx T6, 4.15 mm long Modem Two Torx T6, 4.
Logic Board One Torx T8, 4.5 mm long A (A) - One Torx T8, 5 mm long (B) - One Torx T8, 5.2 mm long B Five identical Torx T8, 6.4 mm long (bronze) Three Torx T8, 4.
PC Card Cage B A (A) - One Torx T8, 5.2 mm long (B) - One Torx T8, 6.5 mm long C (C) - One 4 mm Hex Nut One 5 mm Hex Screw, magnetic, (accessed from keyboard opening) Rib Frame and Heat Exchanger Five identical Torx T8, 4.4 mm long Four identical Torx T8, 5.2 mm long A B (A) - One Torx T8, 16.
Rib Frame and Heat Exchanger (continued) Two identical Torx T8, 16.75 mm long A Three identical (Black) Torx T8, 9.
PowerBook G4 (1GHz/867MHz) Exploded View Battery 661-2740 Bottom Case 922-5443 Hard Drive Screw 922-4502 Hard Drive Rubber Stopper Hard Drive Mounting Bracket 076-0946 Hard Drive Hard Drive Flex Cable 922-4378 AirPort Card 661-2549 AirPort Card Carrier Logic Board 661-1799 (867 MHz) 661-1800 (1 GHz) RJ-11 Modem Port 922-5351 Primary Fan Assembly 922-5459 Thermal Transfer Material 922-4626 Battery Eject Switch Assembly 922-4634 Battery Connector Assembly 922-5046 Modem Cable 4mm Hex Nut Speaker Wire He
