Service Source PowerBook G4 (17-inch) 17 March 2003 © 2003 Apple Computer, Inc. All rights reserved.
Service Source Take Apart PowerBook G4 (17-inch) © 2003 Apple Computer, Inc. All rights reserved.
General Information Overview Some key features that distinguish this computer from earlier PowerBook models include: • 17-inch TFT widescreen display in aluminum alloy enclosure • Built-in Bluetooth • Built-in AirPort Extreme card • Added FireWire 800 port • Uses double-data rate (DDR) memory • Fiber optic backlit keyboard with ambient light sensor New Procedures If you are familiar with taking apart notebook computers, you will notice some differences with this model: • The keyboard is secured with screw
Important Notes • Memory from previous PowerBook models is not compatible with this computer. Do not use older SDRAM DIMMs or SDIMMs even if they fit into the slot. • The Bluetooth module is different from the PowerBook G4 (12-inch). • 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.
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.
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.
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 Tools This procedure requires the following tools: • Soft cloth • #0 Phillips screwdriver Part Location Preliminary Steps Before you begin, remove the battery.
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.
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.
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.
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.
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 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 14 - PowerBook G4 (17-inch) Take Apart 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.
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.
7. Open the display and place the computer on its side. 8. Remove four side screws from both sides.
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.
Replacement Procedure Note: If replacing the top case, remove the keyboard and transfer it to the replacement top case. 1. Verify the thermal pad shown here is in place. If not, check whether it is stuck under the removed top case and replace. If not, install a new pad. 2. Visually check to verify that all cables (highlighted below) are connected and routed correctly with nothing raised up or incorrectly over a component.
3. Check perimeter wiring, where shown, to verify that it will not be caught or pinched by the top case during replacement. 4. Check that display cable brackets are properly seated and secured with screws.
5. 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. 6. 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.
7. 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. 8. On the top case, check cable connections and routing.
9. Check that the perimeter metal tabs are not bent. Note: Do not bend the tabs; the metal quickly fatigues and can break off easily. 10. Lay the top case upside down and locate the flex cable. 11. While pulling the cable up, run a finger along its base to crease it at a 90-degree angle.
12. The cable should point straight up. 13. Open the display to 90-degrees and tilt the computer back so it rests on the back of the display. 14. Guide the top case flex cable through the slot between the logic board and the bottom case frame.
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. 15. Turn the computer to rest on the bottom case. 16. At the left front corner of the computer, insert the top case edges into the bottom case channels, shown. 17. Hold the front of the top case along the front edge of the bottom case and lower into place.
18. 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.
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. 19. Install the front and rear side screws on both sides to hold the top case in place.
20. Carefully close the display, without forcing. If it does not close easily, reinstall the top case, checking for cable routing and clearances. 21. Turn the computer over. 22. 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.
23. 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. 24. 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.
25. 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. 26. 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.
27. Install the other “shoulder” screw in the end screw hole. 28. Install the remaining side screws. 29. Install the logic board screws. 30. Install the remaining bottom screws along the back edge. 31. Install the memory door, and screws. 32. Install the battery bay screws. 33. Visually check the flatness of the top case. If it is not flat, remove it, fix the problem, then reinstall. 34. Replace the battery. 35.
Keyboard Tools This procedure requires the following tools: • #0 Phillips screwdriver • Torx T8 screwdriver (or other blunt tool, 3.
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.
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.
7. Continue until the keyboard can be grasped, then carefully lift it up and guide out its flex cable (shown below).
8. Carefully rub off any adhesive residue left in the keyboard well and on the fiber optics.
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.
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.
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.
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 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 PowerBook G4 (17-inch) Take Apart - 41
Procedure 1. Use the tabs on the connectors to disconnect and remove the sound board flex cable. Note: Remove the connector from the logic board by rocking from side to side. 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).
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. 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 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 44 - PowerBook G4 (17-inch) Take Apart 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.
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 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 PowerBook G4 (17-inch) Take Apart - 47
Procedure 1. Grasp the SuperDrive flex cable connector, where shown, and rock from side to side while pulling up, to disconnect it. 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.
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 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 50 - PowerBook G4 (17-inch) Take Apart 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.
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 52 - PowerBook G4 (17-inch) Take Apart 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 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 54 - PowerBook G4 (17-inch) Take Apart 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.
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.
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.
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. 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 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.
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.
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 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 PowerBook G4 (17-inch) Take Apart - 63
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.
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 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 66 - PowerBook G4 (17-inch) Take Apart 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.
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.
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 Tools This procedure requires the following tools: • Torx T8 screwdriver (magnetized) • X-Acto knife with a new flat-blade • 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).
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 unnecessary flexing.
2. Turn the computer over. Disconnect the cables shown. 3. Remove the twelve screws.
4. Lift the logic board from the left side and pivot along the port side. Note: The thermal material on the bottom side of the board may make it difficult for the board to release (verify that all the screws have been removed). Apply slow constant pressure, avoid over flexing, until it releases. Warning: Flexing the logic board can break solder joints to chips. Avoid unnecessary flexing especially at the narrow neck of the fan cutout. 5. Carefully coax the port end of the board out of the port openings.
Replacement Procedure Warning: Flexing of the logic board can break solder joints to chips. To prevent damage to the board, guard against unnecessary flexing. Do not hold the board by the ports end or by the narrow neck at the fan cutout, as the board’s weight can flex the board at this narrow point. 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. On the back side of the logic board, remove the existing rectangular thermal pad covering two chips, shown below. Important: If the pad is not on the board, check the underside of the top case and remove. 3. From the Thermal Pad Kit (076-1033) install the rectangular shaped pad over the two chips on the replacement logic board, where shown below. Note: Avoid unnecessary contact with either side of the thermal pad as dirt and body oils reduce the thermal pad's conductivity.
4. Use a black stick to remove all the original thermal material on the heatsink at the locations shown below. 5. Vigorously clean remaining residue and adhesive with an alcohol pad. 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.
Note: Avoid unnecessary contact with thermal gel or either side of thermal pads as dirt and body oils reduce the thermal pad's conductivity. 6.
Center that side over the mating surface (raised surface) and evenly apply it, without air pockets, by lightly pressing on the protective backing of the other side. Remove the remaining protective backing. Important: With an X-Acto knife, trim any excess thermal pad material that extends beyond the mating surface, if necessary, to prevent it from touching holes in the heatsink.
7. 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. (The 10 cc dispenser may be graduated in milliliters. Note: 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.
8. If the logic board was removed to facilitate another procedure and will be reinstalled, also remove all the thermal material from the corresponding chips (shown below) in the same manner. Important: Use extreme care not to damage the chips or logic board components.
9. 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. 10. 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. 11. Reassemble and test all ports, components and functions of the computer.
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 82 - PowerBook G4 (17-inch) Take Apart 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.
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.
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.
7. Lift off the display panel and clutch barrel assembly. 8. Remove the clutch spring end caps from both sides.
9. Remove the two screws and torsion bar on each side.
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.
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.
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.
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.
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.
13. 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. 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.
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 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 Heatsink and Fan Assembly PowerBook G4 (17-inch) Take Apart - 95
Procedure Note: The Heatsink and fans are one assembly part. 1. Remove the screws and lift out the heatsink and fan assembly. Important: Do not attempt to transfer fans from one heat sink to another. This can create acoustic issues. Replacement Note: Make sure to clean existing thermal material from the logic board and apply new thermal material (see Logic Board chapter).
Bottom Case Assembly Part Location Preliminary Steps Before you begin, remove the following: • Battery • Top case • Hard drive • Sound board • SuperDrive • Backup battery board • Left and right speakers • Modem • PC card cage & AirPort Extreme assembly • DC-in board • Logic board • Display panel assembly • Heatsink and fan assembly Bottom Case Assembly PowerBook G4 (17-inch) Take Apart - 97
Procedure When all preliminary steps are performed, the bottom case is the part that remains. Verify that the following items are on the replacement bottom case, if not, transfer them from the bottom case being replaced, or install new: • EMI shields • Rubber gasket • Battery connector assembly 1. Reassemble and test all ports, components and functions of the computer, including battery operation.
Service Source Troubleshooting PowerBook G4 (17-inch) © 2003 Apple Computer, Inc. All rights reserved.
General Information Wire and Flex Cables With the very thin enclosure design and dispersed circuit board, a large number of flex cables are used in this computer. In addition, there are a variety of wire cable harnesses as well. Many of these cables carry multiple types of signals. In the case of the DC-in board flex cable; the cable is forked with one path going to the Bluetooth board and the other to the DC-in board. Here is a list of the cables and the signals that run across them.
Cable or Flex Cable Name Signal(s) Running Through It Fan (right) cable (to logic board) Power/control for right fan Hard drive flex cable (to logic board) Hard drive control, data, and power Inverter cable (to inverter board in display panel assembly) High voltage for backlight Inverter cable (to logic board) Display backlight control Keyboard backlight cable (on top case) Power to keyboard backlight LEDs Keyboard flex cable Keyboard data and status lines LVDS cable (from display panel assemb
Potential flex cable and connector issues. ZIF connector locking Bar The locking bar holds the flex cable into the connector. The connector will not work properly if any of the following situations exist: • The locking bar is not completely pushed into the socket on both sides. • The locking bar is broken or missing. Important: In this case the board must be replaced.
The cable is not secured straight. Make sure that the alignment mark, if present, or metal edge of the contacts run parallel to the connector. If the flex cable is inserted crooked, some signals may not be connected or signals may short together. Broken connectors on the flex cable Some flex cables have connector plugs or sockets attached at their ends.
Cables nicked or crimped For cables in the bottom case assembly routed along the front left edge, left side and display clutch areas, check whether the wire insulation has been nicked (exposing bare metal), severed or crimped. If wire insulation has been nicked but the wires are still intact, insulate it with Kapton tape.
Hardware Troubleshooting Tools and Tips Apple Hardware Test 2.0.1 (AHT) Starting with the PowerBook G4 (17-inch), the Apple Hardware Test software will be incorporated into the Software Install and Restore DVD. There is no separate CD for this diagnostic. Previously, the C key was held down to boot into the diagnostics. With the combined DVD, this action will boot into the software restore section of the disk. In order to access the AHT on the DVD follow these steps: 1.
Apple Service Diagnostic Main screen Apple Service Diagnostic Select test tab General Information PowerBook G4 (17-inch) Troubleshooting - 7
Apple Service Diagnostic Hardware info tab Apple Service Diagnostic Test log tab Resetting the Power Manager Unit (PMU) The PMU reset button has been removed from the logic board. Use the following key combination procedure or the PMU Reset pad (see PMU NMI and PMU Reset pads on logic board, below). 1. If the computer is on, turn it off. 2. Reset the power manager by simultaneously pressing and then releasing ShiftControl-Option-power button.
Power-on pads on logic board With the top case removed, the power-on button is disconnected. Instead of having to reconnect the top case to turn on the system, there are two pads on the logic board when shorted together (with a tool like the head of a flat blade screwdriver) is the equivalent to pushing the power-on button. These pads are located about 5cm left of the back left corner of the optical drive, 1-1/2cm above the notch for the top case flex cable. It is marked POWER BUTTON.
PMU NMI and PMU Reset pads on logic board In addition to the power-on button pads on the logic board, there are pads for PMU NMI and PMU reset. These buttons work when their pads are shorted together (with a tool like the head of a flat blade screwdriver). They are marked PMU NMI and PMU RESET. The pads are separated with a white horizontal line between the pads. These pads are located about 1cm left of the back left corner of the optical drive.
Software Troubleshooting Tips and Tools Mac OS X only Starting with the PowerBook G4 (17-inch), the system will no longer boot into Mac OS 9. Mac OS 9 applications can still be used, but only in the Mac OS X classic mode. In locations such as the Startup Disk system preference pane, a Mac OS 9 folder will not show up as an option. Login window and account Mac OS X requires at least one user account to be established. This is the Administrator’s account.
To start up into Safe Mode (to Safe Boot), do this: 1. Be sure the computer is shut down. 2. Press the power button. 3. Immediately after you hear the startup tone, press and hold the Shift key. Note: The Shift key should be held as soon as possible after the startup tone but not before. 4. Release the Shift key when you see the screen the gray Apple and progress indicator (looks like a spinning gear). During the startup, you will see "Safe Boot" on the Mac OS X startup screen (shown below).
Hardware 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.
Power Adapter Note The system was designed to use the Apple 65-Watt Portable Power Adapter that came with your computer. The previous 45-Watt Apple power adapter for PowerBooks is plug compatible, but it may not provide sufficient power during some activities and power may be drawn temporarily from the battery. You can identify the Apple 65W Power Adapter by its markings (see photo).
Startup The computer will not power on (no fan movement, hard drive spin up and display is not lit) 1. Remove any connected peripherals and eject any PC card. 2. Check that the battery has enough charge to start the computer by pressing the button next to the LEDs on the battery. At least one LED must light solid (not flashing). 3. Connect a known-good Apple 65W Portable Power Adapter (661-1798) and power cord or plug to a known-good power outlet; make sure the DC plug is firmly inserted.
Memory error message “The built-in memory test has detected an error” appears on the screen 1. Run Apple Service Diagnostic Test. Note: If the failure is intermittent, run Apple Service Diagnostic Test in loop mode (check looping options under Test Controls tab and select only the RAM test under the Select Tests tab) for an extended time to test the memory. 2. If the test can’t find the memory or finds bad memory, inspect the bad DIMM. Verify proper memory is being used.
Blue screen appears (a spinning disc cursor may also be visible), Prohibitory Sign appears, Restart dialog box appears (Mac OS X 10.2 kernel panic window), or Gray screen during startup Prohibitory Sign Kernel Panic dialog box 1. Make sure all external devices are disconnected and any PC card ejected. If kernel panic goes away, troubleshoot the external device by reconnecting each device until the panic occurs. 2.
Flashing question mark appears on the screen Note: This system will only boot the Mac OS X system that shipped with this computer or later. It does not support booting into Mac OS 9. 1. Start up from the software install and restore DVD 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. When the Disk Utility opens, on the left hand side, all disk and volumes are listed.
System shuts down intermittently Important: This issue can be a result of not using the 65W power adapter with the PowerBook G4 (17-inch) computers. Confirm with the customer which adapter they were using when having this problem. The adapter can be identified by 65W in the name and markings, and the metal securing-stud on the plug connector. 1. Disconnect all external peripherals and eject any PC card. 2. Make sure a known good fully charged battery is fully inserted.
Application Quits, Kernel panic or other booting problems 1. If a specific application quits, replace the application. Verify the application is compatible with OS X. 2. Clear parameter RAM. Hold down Command-Option-P-R during startup until you hear a second startup chime. 3. Run Disk Utility from the Software Install and Restore DVD. 4. Perform a clean install of system software with the software install and restore disc that came with the computer.
Computer beeps twice at startup 1. Two beeps means that EDO memory is installed in the RAM expansion slot. The PowerBook does not accept EDO memory. 2. Replace RAM card(s) with known-good and compatible RAM and restart. • If symptom repeats, replace logic board. Computer beeps three times at startup 1. Three beeps means that no RAM banks passed memory testing. 2. If a RAM card is installed in the upper expansion slot (if not, skip to next step), remove it and restart.
AirPort Extreme Card AirPort Extreme Card not recognized 1. In Mac OS X, use Software Update in system preferences or see the Apple Software Updates web page to make sure the latest version of AirPort Extreme software is installed. 2. Restart the computer. 3. Open AirPort in system preferences and make sure AirPort is on and Base Station is selected. 4. Check the AirPort Extreme Card flex cable connection to the logic board. 5. Remove and reinstall the AirPort Extreme software. 6.
Battery Battery will not eject 1. Flip over the unit and slide both battery latches towards the back of the system, exposing two orange labels. The latches should stay in an open state. 2. If the battery does not pop up, use a small plastic flat-blade tool to pry up the battery around the battery latch. 3. Verify proper latch operation, by exercising the latch. If it does not move smoothly or evenly, replace the bottom case. 4.
4. Try known-good battery. If it charges, replace the battery. If doesn’t charge, check the battery connector and its connection to the logic board. 5. Replace the battery connector assembly (requires removing the logic board). 6. Turn off the computer. Perform the keyboard PMU reset procedure described in the Hardware Troubleshooting Tools and Tips section. Wait five seconds before continuing. Press the power button to start the computer.
Display Display latch not working Note: When the display is being closed, hooks in the top of the display housing should be magnetically pulled down to the latch. When the latch button is pushed, the hook should release and retract into the display housing. 1. Verify hook operation by using a small low-power magnet to exercise the latch mechanism. Make sure hooks are not bent. 2. If the hook does not operate properly, replace the display panel assembly. 3.
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.
Keyboard No response from any key on keyboard 1. Remove any connected peripherals and eject any PC card. 2. Attach an external USB keyboard, if it doesn’t work, go to step 7. 3. Turn off the computer. Check the top case flex cable connection to the logic board (under the lower RAM, if installed). 4. Inspect the top case and keyboard flex cable connectors and cables. If the top case flex cable looks bad, replace top case. 5.
2. Check the keyboard backlight cable connection to the top case flex cable and the top case flex cable connection to the logic board. If the connections look good, change the top case. 3. Replace logic board. Half keyboard is illuminated. 1. Check the keyboard backlight cable connection to the top case flex cable and the top case flex cable connection to the logic board. If the connections look good, change the top case. Microphone The microphone is not working 1.
Modem No modem dial tone 1. Check that the correct modem is selected in the Network Port Configuration section of the Network system preferences. 2. Verify known-good analog (not digital) telephone line. 3. Verify known-good RJ-11 telephone cable. 4. Verify RJ-11 cable is not plugged into Ethernet port. 5. Inspect RJ-11 connector and modem port for pin damage. 6. Verify RJ-11 telephone cable is firmly installed in the modem port. 7.
Optical Drive The optical drive does not accept CD or DVD disc (mechanical failure) 1. Verify disc is not warped and is a 12 cm circular disc. 2. Check that a small disc is not stuck inside, or other foreign objects. Remove drive from system to extract disc. 3. Verify disc is pushed almost all the way into the slot. 4. Check the optical drive flex cable. 5. Replace optical drive. The disc icon does not show up on desktop, or a dialog box appears to initialize disc, when inserting a read-only disc 1.
PC Card PC Card will not insert into the PC Card slot 1. Make sure the PC Card eject button is in, before attempting to insert a PC Card. 2. Make sure the PC Card is right side up (cards are keyed and cannot be inserted upside down). 3. Verify the PC Card is not warped or damaged in any way; if so replace the card. 4. Try a different PC Card. 5. Carefully raise the PC Card slot cover and check for a foreign object inside the slot. 6.
Ports A USB port is not recognizing devices 1. Completely shut down, then press the power button to start the computer. 2. Use Software Update system preferences to verify that the latest software is installed. 3. For USB, test ports with an Apple keyboard or mouse. If the left port is not recognized check the DC-in flex cable’s condition and connection. If the right port is not recognized check the backup battery flex cable’s condition and connection. 4.
3. Make sure the cables are firmly attached. 4. Try a different cable. 5. If self powered make sure that the power supply is connected and device's LED indicates that it is getting power. 6. Replace logic board. Sound No sound heard and the Speakers section of the Sound system preference pane indicates that an external device is plugged in (to the headphone jack or USB ports) 1.
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 system preference pane). 8. Verify that the speaker cable is connected properly to sound board. 9. Check speaker cable. Verify left and right cable connections. 10.
Trackpad The cursor does not move when you are using trackpad 1. Verify that no USB device is connected. 2. Boot from the Software Install and Restore DVD to verify that it is not a software problem. 3. Reset the power manager by pressing the key combination Control-Option-Shift Power. Note: Make sure you do not hold down the "fn" key when resetting the power manager. 4. Check top case flex cable connection to the logic board (under the lower RAM, if installed). 5.
Video No display, or dim display, but computer appears to operate correctly 1. Remove any connected peripherals. 2. Make sure F1 key is not stuck down. 3. Press the F2 key (with the fn key pressed and not pressed) to increase the screen brightness settings. 4. Reboot the computer—hold down the Control and Command keys and press the Power button to restart the computer. Or, press and hold the Power button for 5 to 10 seconds to shut down the computer, then press the Power button to restart. 5.
Misc. Symptoms 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. • 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.
8. Shut down system. 9. Replace sound board. 10. Replace logic board.
Service Source Views PowerBook G4 (17-inch) © 2003 Apple Computer, Inc. All rights reserved.
Clutch Spring End Cap Kit (Left & Right) 076-1029 Display Panel Assembly 661-2824 Keyboard 922-5776 Top Case Assembly 922-5778 DC-in/Bluetooth/USB Flex Cable 922-5771 DC-in Board Cable 922-5777 RJ-11 Port Assembly 922-5775 DC-in Board 922-5769 Bluetooth Board 922-5833 Ambient Light Sensor Dust Covers (Left & Right) 076-1008 Speaker Assembly 922-5773 Modem Flex Cable 922-5774 Modem 661-2843 PC Card Cage Assembly 922-5825 AirPort Extreme Antenna Jumpber 922-5783 AirPort Extreme Card Assembly 661-2765 Soun