Apple PowerBook G4 Service Source

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Apple POWERBOOK G4 Laptop PDF Service source

  • Model: POWERBOOK G4
  • Brand: Apple
  • Type: Service source
  • Category: Laptop
  • File Size:
  • No. of pages: 204
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1 Page 1 of Apple POWERBOOK G4 Service source

POWERBOOK G4 © 2005 Apple Computer, Inc. All rights reserved.  Service Source PowerBook G4 (15-inch Double-Layer SD) 19 October 2005 (...)

2 Page 2 of Apple POWERBOOK G4 Service source

Apple POWERBOOK G4 Service source © 2005 Apple Computer, Inc. All rights reserved.  Service Source Basics PowerBook G4 (15-inch Double-Layer SD) (...)

3 Page 3 of Apple POWERBOOK G4 Service source

Apple POWERBOOK G4 Service source PowerBook G4 (15-inch Double-Layer SD) Basics - 1 General Information General Information Overview From the exterior, the PowerBook G4 (15-inch Double-Layer SD) physically is identical to its predecessor, the PowerBook G4 (15-inch 1.67/1.5GHz). Both lack the customer accessible AirPort door in the battery bay. (...)

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POWERBOOK G4 2 - PowerBook G4 (15-inch Double-Layer SD) Basics General Information The quickest ways to identify the PowerBook G4 (15-inch Double-Layer SD) computer: • If the system is bootable, power it on. After pressing the power button the sleep LED light comes on solid and stays on until video appears onscreen. • Also the "About this Mac." Under Memory, shows DDR2 memory. • Check a memory card to see if it is DDR2 (keyed (...)

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Apple POWERBOOK G4 Manual PowerBook G4 (15-inch Double-Layer SD) Basics - 3 General Information • With the top case removed, there is no mid-range speaker module (which has been above the hard drive on all previous aluminum PowerBook G4 15-inch models). Main feature differences from the previous models: • Higher resolution 15.2-inch display, 1440 x 960, 114 dpi (previously 1280 x 854, 101 dpi) • Supports DDR2 memory up to 2GB • 128MB VRAM with d (...)

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Apple POWERBOOK G4 Service source 4 - PowerBook G4 (15-inch Double-Layer SD) Basics General Information New Parts and Procedures • Main Battery – The main battery has a new capacity sensing circuit design. It looks the same as previous batteries and is interchangeable. However, it has a different battery calibration procedure. A new calibration procedure has been developed which works on both batteries. Look in the Troubleshooting section, Battery Short (...)

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Apple POWERBOOK G4 Service source PowerBook G4 (15-inch Double-Layer SD) Basics - 5 General Information Important Memory Note Memory from previous 15-inch (Titanium-series) PowerBooks is not compatible with this computer. Memory from previous PowerBook G4 (15-inch FW800), PowerBook G4 (15-inch 1.5/ 1.33GHz), and PowerBook G4 (15-inch 1.67/1.5GHz) is physically not compatible. DDR2 is keyed differently than DDR memory. Service Manual Note In this manua (...)

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POWERBOOK G4 6 - PowerBook G4 (15-inch Double-Layer SD) Basics General Information Tools The following tools are recommended for the take apart procedures. • ESD wrist strap and mat • Soft cloth • #0 Phillips screwdriver (magnetized) • #1 Phillips screwdriver (magnetized) • 5 mm socket wrench • 1.5 mm Hex key (or Torx T6) • Needlenose pliers • Torx T8 screwdriver • Torx T6 screwdriver • Thermal grease (922-7144) • G (...)

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Apple POWERBOOK G4 Laptop Manual PowerBook G4 (15-inch Double-Layer SD) Basics - 7 Kapton Tape Kapton Tape Tools This procedure requires the following tools: • Kapton tape (922-1731 (0.5-inch x 12-yard roll)) • Scissors or tape dispenser Procedure Kapton tape is used to secure cables and connectors where necessary. During disassembly, note any Kapton tape use and locations—reapply in the same manner. Do not over apply or build up tape on top o (...)

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Apple POWERBOOK G4 Manual © 2005 Apple Computer, Inc. All rights reserved.  Service Source Take Apart PowerBook G4 (15-inch Double-Layer SD) (...)

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Apple POWERBOOK G4 Laptop Manual PowerBook G4 (15-inch Double-Layer SD) Take Apart - 1 Foot Foot Tools This procedure requires the following tools: • Foot kit • Tweezers or needlenose pliers • Soft cloth Preliminary Step Before you begin, check the foot location that needs replacement and verify that the case plug is attached. Also verify that the case plug, and the case foot in the kit, match the pictures below. Plug Area on Bottom (...)

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Apple POWERBOOK G4 Service source 2 - PowerBook G4 (15-inch Double-Layer SD) Take Apart Foot Procedure Warning: The glue used in this procedure can bond instantly to skin. Do not touch the glue. In the event of contact, review the safety instructions at the end of this document. For additional information, refer to the glue manufacturer: Elmer's Products, Inc. Columbus, OH. 43215-3799 www.krazyglue.com 1. Place the computer upside down on a clean, (...)

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Apple POWERBOOK G4 Service source PowerBook G4 (15-inch Double-Layer SD) Take Apart - 3 Foot 4. Warning: GLUE IS AN EYE AND SKIN IRRITANT. BONDS SKIN INSTANTLY. Do not touch the glue at any time. Before opening the glue, review the safety instructions at the end of this document. Important: The glue tube included in the kit is sealed until first use. Do not break the seal until you are ready to use the glue. To break the seal, hold the tube upright (...)

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Apple POWERBOOK G4 Service source 4 - PowerBook G4 (15-inch Double-Layer SD) Take Apart Battery Battery Tools This procedure requires the following tools: • Soft cloth • Coin 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. (...)

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Apple POWERBOOK G4 Service source PowerBook G4 (15-inch Double-Layer SD) Take Apart - 5 Battery Procedure Warning: If the computer has been recently operating, allow it to cool down before performing this procedure. 1. Shut down the computer. 2. Disconnect the power cord and any other cables connected to the computer. 3. Place the computer face down on a soft cloth. 4. Insert a coin in the battery lock slot and turn it one quarter turn clockwise. The ba (...)

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Apple POWERBOOK G4 Service source 6 - PowerBook G4 (15-inch Double-Layer SD) Take Apart Memory Door and Memory Cards Memory Door and Memory Cards Tools This procedure requires the following tools: • Soft cloth • #0 Phillips screwdriver Part Location Preliminary Steps Before you begin, remove the battery. (...)

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Apple POWERBOOK G4 Service source PowerBook G4 (15-inch Double-Layer SD) Take Apart - 7 Memory Door and Memory Cards Procedure Warning: If the computer has been recently operating, allow it to cool down before performing this procedure. 1. Place the computer face down on a soft cloth. 2. Remove the four screws from the memory door then remove the door. Note: If only one memory card is installed, the factory installs it in the bottom memory slot. (...)

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Apple POWERBOOK G4 Service source 8 - PowerBook G4 (15-inch Double-Layer SD) Take Apart Memory Door and Memory Cards 3. To remove memory cards, carefully spread the two locking tabs for the slot (top or bottom) away from the card on both sides and allow the card to pop up slightly. 4. Pull the card straight back and out of the memory slot. (...)

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POWERBOOK G4 PowerBook G4 (15-inch Double-Layer SD) Take Apart - 9 Memory Door and Memory Cards Replacement Procedure Notes: • DDR memory cards do not fit in this slot (different notch location). • The top and bottom memory cards are inserted at different angles. • If installing two cards, install into the bottom slot first. • Align the notch in the memory card with the tooth in the slot before inserting. 1. To install a m (...)

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POWERBOOK G4 10 - PowerBook G4 (15-inch Double-Layer SD) Take Apart Memory Door and Memory Cards 2. Slide the card forward to the lower slot. Firmly push the card straight into the slot until it is fully and securely seated along its length. Note: If the back of the card drops down before it is fully seated, raise it up enough to push it fully into the slot. 3. Carefully spread the two locking tabs for the bottom slot away from the car (...)

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Apple POWERBOOK G4 Manual PowerBook G4 (15-inch Double-Layer SD) Take Apart - 11 Memory Door and Memory Cards 4. If installing a memory card in the top slot, follow the same procedures as the bottom slot except insert the card at a 30-degree angle, above the locking tabs. 5. Push the card in until it is firmly seated. 6. As with the bottom slot, spread the locking tabs for the top slot while pushing the card straight down until it locks into place. (...)

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Apple POWERBOOK G4 Manual 12 - PowerBook G4 (15-inch Double-Layer SD) Take Apart Memory Door and Memory Cards 7. Cards should be flat and secure on both sides. 8. Install the memory door. 9. Replace the battery. 10. 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.) (...)

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Apple POWERBOOK G4 Manual PowerBook G4 (15-inch Double-Layer SD) Take Apart - 13 Top Case Top Case Tools This procedure requires the following tools: • #0 Phillips screwdriver (magnetized) • 1.5 mm Hex key (or Torx T6) • Black stick (or other nonconductive nylon or plastic flat-blade tool) • Soft cloth • Multi-compartment screw tray Part Location (...)

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Apple POWERBOOK G4 Manual 14 - PowerBook G4 (15-inch Double-Layer SD) Take Apart Top Case Preliminary Steps Before you begin, remove the following: • Battery • Memory door Procedure Note: This procedure removes the top case and keyboard assembly. The keyboard is removable only after removing the top case. 1. Place the computer face down on a soft cloth. 2. Remove the two screws inside the battery bay. 3. Remove the two screws from the (...)

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Apple POWERBOOK G4 Manual PowerBook G4 (15-inch Double-Layer SD) Take Apart - 15 Top Case 5. With the display open, rest the computer on one side. Remove the three screws. 6. Turn over the computer and remove the three screws on the other side. 922-6091 3.4 mm 922-6091 3.4 mm (...)

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Apple POWERBOOK G4 Laptop Manual 16 - PowerBook G4 (15-inch Double-Layer SD) Take Apart Top Case 7. Open the computer slightly and rest it with the back facing up. Remove the two top screws along the back. Note: Do not remove the bottom screws. 8. Lay the computer right side up and open the display slightly past 90-degrees. 9. Remove the two hex screws at the back corners of the top case (a Torx T6 can also be used). 922-6100 5.3 mm 4.4 mm 922-6096 1.5 mm (...)

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POWERBOOK G4 PowerBook G4 (15-inch Double-Layer SD) Take Apart - 17 Top Case 10. Along the left side, near the back, insert a black stick into the space between the top and bottom case. Work the black stick forward with a twisting motion until the black stick can be inserted on the left side of the front. (...)

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POWERBOOK G4 18 - PowerBook G4 (15-inch Double-Layer SD) Take Apart Top Case 11. Loosen the back right side, if needed. 12. Work the left side up until the four catches over the optical drive slot release along the right side, then lift the top case straight up, slightly, to release it completely, but do not remove. (...)

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POWERBOOK G4 PowerBook G4 (15-inch Double-Layer SD) Take Apart - 19 Top Case 13. Lift the front of the top case and pivot along the back edge to about 45-degrees, to expose the keyboard flex cable connected to the logic board. Important: Do not lift off the top case or strain the keyboard flex cable. 14. Remove any Kapton tape from the keyboard connector on the logic board, then use a black stick to disconnect the flex cable. Lift (...)

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Apple POWERBOOK G4 Laptop Manual 20 - PowerBook G4 (15-inch Double-Layer SD) Take Apart Top Case Replacement Procedure Note: If replacing the top case, remove the keyboard and transfer to the replacement top case. 1. Visually check to verify that all cables are connected and routed correctly with nothing raised up or incorrectly over a component. 2. Check perimeter wiring and cables around clutches to verify that they will not be caught or pinched by the top c (...)

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Apple POWERBOOK G4 Manual PowerBook G4 (15-inch Double-Layer SD) Take Apart - 21 Top Case 5. Check that the perimeter metal tabs are not bent. Note: The metal quickly fatigues and can break off easily. Be extremely careful to gently straighten tabs, if needed. 6. Connect the flex cable from the top case to the logic board. 7. Lift the top case slightly and rotate it down over the bottom case (verify that the cable is folding properly) and align the corners (...)

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Apple POWERBOOK G4 Laptop Manual 22 - PowerBook G4 (15-inch Double-Layer SD) Take Apart Top Case Important Notes: • Some side screws have a flexible screw boss. If they block a tab on the top case from seating, use the pointed end of a black stick through the screw hole to push on the boss slightly. • The tabs are fragile. Do not apply too much pressure or bend them. • The top case should lay flat along the sides and top, if not, make sure that cables and c (...)

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Apple POWERBOOK G4 Manual PowerBook G4 (15-inch Double-Layer SD) Take Apart - 23 Top Case 10. Close the computer, flip it over, and install the four back screws. 11. Install the two screws in the memory bay. 12. Install the memory door and four screws. 13. Install the two screw in the battery bay. 14. Replace the battery. 15. Testing the computer should include powering on, checking the keyboard and trackpad function. Operate the computer in a darkened roo (...)

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Apple POWERBOOK G4 Laptop Manual 24 - PowerBook G4 (15-inch Double-Layer SD) Take Apart Keyboard Keyboard Tools This procedure requires the following tools: • #0 Phillips screwdriver • Black stick (or other nonconductive nylon or plastic flat-blade tool) • Kapton tape Part Location Preliminary Steps Before you begin, remove the following: • Battery • Top case (...)

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Apple POWERBOOK G4 Service source PowerBook G4 (15-inch Double-Layer SD) Take Apart - 25 Keyboard Procedure Keyboard for the PowerBook G4 (15-inch Double-Layer SD) and (15-inch 1.67/1.5GHz) computers have different construction, and removal and installation procedures than previous models. Important Notes: • The PowerBook G4 (15-inch Double-Layer SD) keyboards are not interchangeable with previous models. Verify that the correct replacement keyboard is ordered, a (...)

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Apple POWERBOOK G4 Service source 26 - PowerBook G4 (15-inch Double-Layer SD) Take Apart Keyboard 3. Very carefully lift the front of the two connectors to release the keyboard flex cables, as shown. Important: The connectors are delicate. If damaged, the top case must be replaced. Replacement Note: Verify that the cables are fully inserted and secured straight. 4. Note the position, then carefully peel off the insulator film covering the back of the keyboard well (...)

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POWERBOOK G4 PowerBook G4 (15-inch Double-Layer SD) Take Apart - 27 Keyboard 5. Use needlenose pliers to straighten the four bend-tabs located along the bottom edge, as shown. These tabs lock down and stiffen the top edge of the keyboard. Important: The bend-tabs are delicate. Bend them carefully to avoid damage. Avoid overbending. 6. Remove the ten keyboard screws. 922-6718 1.6 mm (...)

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POWERBOOK G4 28 - PowerBook G4 (15-inch Double-Layer SD) Take Apart Keyboard 7. Note the six insert-tabs along the middle edge, and two on each side. The following procedures release these tabs so that the keyboard can be removed. 8. To prevent the keyboard from falling out, support it with your hand, and raise the top case up vertically. Note: The keyboard does not have adhesive under it, as in previous models. (...)

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Apple POWERBOOK G4 Manual PowerBook G4 (15-inch Double-Layer SD) Take Apart - 29 Keyboard 9. If needed, push through one of the top center keyboard screw holes, with the point of a black stick, to bow out the keyboard slightly. Important: Ensure that the hole used is a screw hole, or damage to other sensitive components may result. A black stick is used to avoid damaging the screw boss threads—do not use a metal tool. 10. Important: During this procedure, (...)

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Apple POWERBOOK G4 Laptop Manual 30 - PowerBook G4 (15-inch Double-Layer SD) Take Apart Keyboard 11. Use your finger to hold the bowed out keyboard. Continue to bow it out only enough for the tabs on one side of the keyboard to release cleanly. Repeat for the other side. Important: Do not bow the keyboard too much, or it may become permanently bent. (...)

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Apple POWERBOOK G4 Manual PowerBook G4 (15-inch Double-Layer SD) Take Apart - 31 Keyboard 12. Lift the keyboard up to release the tabs along the bottom edge and carefully thread out the flex cables. (...)

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POWERBOOK G4 32 - PowerBook G4 (15-inch Double-Layer SD) Take Apart Keyboard Replacement Procedure When replacing the keyboard, here are some key points to ensure: • Prevention of scratches to the cosmetics of the top case • All tabs are properly seated • Keyboard lays flat • Cables not caught • Bend-tabs are not damaged • Screw holes align • Cable connectors are not damaged and cables secure properly • Kapton tape is applied as bef (...)

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POWERBOOK G4 PowerBook G4 (15-inch Double-Layer SD) Take Apart - 33 Keyboard 2. Guide the keyboard’s flex cables through the slot in the top case, as shown. Make sure that they do not catch or bend behind the keyboard. 3. Lower the keyboard and seat all six tabs along the bottom, so that the keyboard sits flat and straight. (...)

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Apple POWERBOOK G4 Service source 34 - PowerBook G4 (15-inch Double-Layer SD) Take Apart Keyboard Important: During the next steps, do not allow the tabs or metal edge of the keyboard to scrape along the cosmetic surface of the top case, or damage can result. 4. While ensuring that the keyboard bottom stays straight and secure, hold the top of the keyboard in the middle, then with your other hand, bow in one side of the keyboard to engage the two tabs at the top int (...)

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Apple POWERBOOK G4 Service source PowerBook G4 (15-inch Double-Layer SD) Take Apart - 35 Keyboard 5. Use the heel of your hand to hold in place the edge of the keyboard that was just inserted while holding the top of the keyboard with a finger on that hand, then use your other hand to help bow in the remaining side of the keyboard until it can be engaged. (...)

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Apple POWERBOOK G4 Service source 36 - PowerBook G4 (15-inch Double-Layer SD) Take Apart Keyboard 6. While supporting the keyboard in the top case, verify that the keyboard lays flat and that all the tabs have seated properly. Note: The keyboard will not sit flat if any of the tabs have not seated properly. If the side tabs are not seating or are binding, check the bottom edge of the keyboard to verify that all the tabs are seated and the bottom of the keyboard is (...)

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Apple POWERBOOK G4 Laptop Manual PowerBook G4 (15-inch Double-Layer SD) Take Apart - 37 Keyboard 12. Insert the flex cables into their connectors and secure. Install Kapton tape in the same location as it was removed. 13. Replace the insulator film in the same locations as they were removed. Ensure the holes in the film match up correctly with the screw bosses. Avoid wrinkles and bulges. If installing a replacement top case, use the new film if supplied. Import (...)

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Apple POWERBOOK G4 Laptop Manual 38 - PowerBook G4 (15-inch Double-Layer SD) Take Apart Backup Battery Backup Battery Tools This procedure requires the following tools: • Black stick (or other nonconductive nylon or plastic flat-blade tool) Part Location Preliminary Steps Before you begin, remove the following: • Battery • Top case (...)

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Apple POWERBOOK G4 Laptop Manual PowerBook G4 (15-inch Double-Layer SD) Take Apart - 39 Backup Battery Procedure Note: Previous model battery shown. 1. Use a black stick to release the adhesive holding the backup battery to the optical drive then disconnect the backup battery cable. Note: The backup battery is held down by double-backed tape adhesive on its cover. (...)

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Apple POWERBOOK G4 Laptop Manual 40 - PowerBook G4 (15-inch Double-Layer SD) Take Apart Backup Battery Replacement Procedure 1. Connect the backup battery cable to the backup battery and to the logic board. 2. Remove any protective adhesive cover on the replacement backup battery. 3. Position the backup battery precisely to the dimensions shown below. Note: Measurements are from the edge of the optical drive and the optical drive bracket to the backup battery board a (...)

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Apple POWERBOOK G4 Service source PowerBook G4 (15-inch Double-Layer SD) Take Apart - 41 Backup Battery 4. Press where shown to secure the backup battery to the optical drive. 5. Reassemble the computer. 6. 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 fi (...)

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Apple POWERBOOK G4 Laptop Manual 42 - PowerBook G4 (15-inch Double-Layer SD) Take Apart Battery Connector Battery Connector Tools This procedure requires the following tools: • #0 Phillips 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 (...)

53 Page 53 of Apple POWERBOOK G4 Service source

POWERBOOK G4 PowerBook G4 (15-inch Double-Layer SD) Take Apart - 43 Battery Connector Procedure 1. Remove three screws. 2. Install the battery connector and ground screw lead. Note: Do not overtighten the two main battery connector screws. There will be play in the battery connector when the screws are secured. 3. Connect the main cable to its connector on the underside of the logic board. 4. Reassemble the computer. 5. Testing should include plu (...)

54 Page 54 of Apple POWERBOOK G4 Service source

Apple POWERBOOK G4 Laptop Manual 44 - PowerBook G4 (15-inch Double-Layer SD) Take Apart Left Blower Left Blower Tools This procedure requires the following tools: • #0 Phillips 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 Note: Replacing the right blower requires removing the logic board. (...)

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POWERBOOK G4 PowerBook G4 (15-inch Double-Layer SD) Take Apart - 45 Left Blower Procedure 1. Disconnect the four cables shown below. 2. Remove four screws. 922-6093 4.5 mm (...)

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POWERBOOK G4 46 - PowerBook G4 (15-inch Double-Layer SD) Take Apart Left Blower 3. Carefully separate any tape used to seal the back edge as you lift out the blower. 4. Install replacement blower. Use Kapton tape to seal as necessary. 5. Use Kapton tape to ensure that the cables lay flat, and that wires will not move into the PC card cage. 6. Reassemble and test computer. Replacement Note: Ensure that Kapton tape is installed over the fins of th (...)

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Apple POWERBOOK G4 Service source PowerBook G4 (15-inch Double-Layer SD) Take Apart - 47 Optical Drive Optical Drive Tools This procedure requires the following tools: • #0 Phillips screwdriver (magnetized) • Thin double-back tape (if the backup battery will not re-stick securely) • Black stick (or other nonconductive nylon or plastic flat-blade tool) Part Location Preliminary Steps Before you begin, remove the following: • Battery • Top case • Backup batte (...)

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POWERBOOK G4 48 - PowerBook G4 (15-inch Double-Layer SD) Take Apart Optical Drive Procedure 1. Remove the three screws from the drive holder. 2. Lift out the bracket. Replacement Note: Verify that the EMI gasket is securely in place. 922-6097 6.4 mm (...)

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POWERBOOK G4 PowerBook G4 (15-inch Double-Layer SD) Take Apart - 49 Optical Drive 3. Use a black stick to carefully disconnect the optical drive flex cable connector. 4. Remove the screw, shown. 5. Lift up at the rear of the drive and remove. Warning: Hold the optical drive at its side edges. Do not put pressure in the middle. 922-6090 3.2 mm (...)

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Apple POWERBOOK G4 Manual 50 - PowerBook G4 (15-inch Double-Layer SD) Take Apart Optical Drive 6. Transfer the flex cable, side brackets and screws to the replacement optical drive. 7. Transfer the cosmetic cover to the replacement optical drive. 922-6488 2.15 mm (...)

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Apple POWERBOOK G4 Laptop Manual PowerBook G4 (15-inch Double-Layer SD) Take Apart - 51 Optical Drive 8. To install the replacement optical drive, insert the front of the drive and ensure that the holes in the front brackets fit over the pins on the internal frame, while lowering the back of the drive into place. 9. Verify that both sides of the drive are fully seated, and reinstall the screw. 10. Connect the optical drive flex cable connector to the logic board. (...)

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POWERBOOK G4 52 - PowerBook G4 (15-inch Double-Layer SD) Take Apart Optical Drive How to remove a stuck disc from an MKE optical drive Important: These procedures apply to MKE optical drives, only. 1. Remove the four identical screws that hold the top cover to the drive. 2. Slide the top cover approximately 2 mm toward the back of the drive. Lift up the top cover to remove it. (...)

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POWERBOOK G4 PowerBook G4 (15-inch Double-Layer SD) Take Apart - 53 Optical Drive 3. Check the placement of the disc. It is either clamped to the turntable at the center of the disc, or it is wedged under one or more posts at the outer edge of the disc. 4. Holding the edge of the disc, press on the center clamp or hold the posts steady as you remove the disc from the drive. Important: Do not touch any key components located near the disc. 5. Re (...)

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Apple POWERBOOK G4 Laptop Manual 54 - PowerBook G4 (15-inch Double-Layer SD) Take Apart Hard Drive Hard Drive Tools This procedure requires the following tools: • #0 Phillips 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 (...)

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Apple POWERBOOK G4 Service source PowerBook G4 (15-inch Double-Layer SD) Take Apart - 55 Hard Drive Procedure 1. Remove the three screws from the drive holder. 2. Lift out the bracket. 922-6097 6.4 mm (...)

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Apple POWERBOOK G4 Service source 56 - PowerBook G4 (15-inch Double-Layer SD) Take Apart Hard Drive 3. Use a black stick to carefully disconnect the hard drive flex cable connector. 4. Lift up on the right side of the hard drive to remove. (...)

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POWERBOOK G4 PowerBook G4 (15-inch Double-Layer SD) Take Apart - 57 Hard Drive 5. Transfer the shield, side screws, rubber shockpads and the flex cable to the replacement hard drive. 6. Install the replacement hard drive and reassemble the computer. 7. When installing the replacement drive... to avoid exposing the hard drive flex cable contacts, as shown here,... 922-6083 5.8 mm (...)

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Apple POWERBOOK G4 Manual 58 - PowerBook G4 (15-inch Double-Layer SD) Take Apart Hard Drive use a black stick to guide the foam (covering the contacts) past the logic board, while... guiding the rubber shockpads securely into the holes in the hard drive holder. (...)

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Apple POWERBOOK G4 Manual PowerBook G4 (15-inch Double-Layer SD) Take Apart - 59 Hard Drive 8. Make sure all shockpads are seated correctly. 9. When replacing the hard drive/optical drive holder, make sure that the Mylar shield is not caught. 10. Testing the computer should include powering on, keyboard and trackpad function, verify that the hard drive is recognized, and that the speakers, and modem works. (...)

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Apple POWERBOOK G4 Manual 60 - PowerBook G4 (15-inch Double-Layer SD) Take Apart Sleep LED Sleep LED Tools This procedure requires the following tools: • #0 Phillips 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 (...)

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Apple POWERBOOK G4 Laptop Manual PowerBook G4 (15-inch Double-Layer SD) Take Apart - 61 Sleep LED Procedure 1. Remove the screw. 2. Follow the Sleep LED board wire to its connector on the logic board and disconnect it. Lift up any Kapton tape to release the cable, and replace during reinstallation. 3. Testing the computer should include sleep LED function, hard drive, keyboard and trackpad. 922-6093 4.5 mm (...)

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Apple POWERBOOK G4 Service source 62 - PowerBook G4 (15-inch Double-Layer SD) Take Apart Right Speaker Right Speaker Tools This procedure requires the following tools: • #1 Phillips 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 (...)

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Apple POWERBOOK G4 Manual PowerBook G4 (15-inch Double-Layer SD) Take Apart - 63 Right Speaker Procedure 1. Remove one screw. 2. Use a black stick to carefully pry out the speaker, as shown. Note: The right speaker is an assembly that contains the right ambient light sensor lens. Do not disassemble. 922-6475 9.5 mm (...)

74 Page 74 of Apple POWERBOOK G4 Service source

Apple POWERBOOK G4 Laptop Manual 64 - PowerBook G4 (15-inch Double-Layer SD) Take Apart Right Speaker 3. Follow the speaker’s wire to the main speaker cable connector and disconnect it. Note: Lift Kapton tape as needed and note the wire routing for reinstallation. Replace Kapton tape when reinstalling. 4. To install the right speaker, line up the screw hole in the ALS lens with the hole in the logic board, then press on the hard plastic that surrounds the flexibl (...)

75 Page 75 of Apple POWERBOOK G4 Service source

Apple POWERBOOK G4 Laptop Manual PowerBook G4 (15-inch Double-Layer SD) Take Apart - 65 Right Speaker 5. Route the speaker cable under flex cables and along the path shown below. Secure in place with Kapton tape as needed. 6. Reassemble the computer and test the speakers, including using the Sound system- preference pane. (...)

76 Page 76 of Apple POWERBOOK G4 Service source

Apple POWERBOOK G4 Service source 66 - PowerBook G4 (15-inch Double-Layer SD) Take Apart Left Ambient Light Sensor (ALS) Left Ambient Light Sensor (ALS) Important: • The left ALS cable connects to the logic board in the same connector type and same general location as the inverter cable. Make sure to connect to the correct connector. Tools This procedure requires the following tools: • #0 Phillips screwdriver (magnetized) • Black stick (or other nonconductive (...)

77 Page 77 of Apple POWERBOOK G4 Service source

POWERBOOK G4 PowerBook G4 (15-inch Double-Layer SD) Take Apart - 67 Left Ambient Light Sensor (ALS) Procedure 1. Remove the two screws and disconnect the flex cable, shown. 2. Lift the flex cable and disconnect the ALS cable from the logic board. 3. Replacement Note: Verify that the cable is connected to the correct connector on the logic board, as shown above. 4. Reassemble the computer and test the ambient light sensor operation, trackpad, and (...)

78 Page 78 of Apple POWERBOOK G4 Service source

Apple POWERBOOK G4 Service source 68 - PowerBook G4 (15-inch Double-Layer SD) Take Apart Left Speaker Left Speaker Tools This procedure requires the following tools: • 4mm Hex socket wrench • 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 ambient light sensor (...)

79 Page 79 of Apple POWERBOOK G4 Service source

POWERBOOK G4 PowerBook G4 (15-inch Double-Layer SD) Take Apart - 69 Left Speaker Procedure 1. Remove the hex nut. 2. Lift the speaker slightly to reveal the speaker wire connector and disconnect. 3. Reassemble the computer and test the speakers, including using the Sound system- preference pane. 922-5840 4 mm (...)

80 Page 80 of Apple POWERBOOK G4 Service source

Apple POWERBOOK G4 Laptop Manual 70 - PowerBook G4 (15-inch Double-Layer SD) Take Apart PC Card Cage PC Card Cage Tools This procedure requires the following tools: • #0 Phillips 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 ambient light sensor board • Left speaker (...)

81 Page 81 of Apple POWERBOOK G4 Service source

Apple POWERBOOK G4 Manual PowerBook G4 (15-inch Double-Layer SD) Take Apart - 71 PC Card Cage Procedure 1. Use a black stick to disconnect the PC card cage flex cable. 2. Remove the four screws. 922-6093 4.5 mm 922-6470 6.6 mm (...)

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Apple POWERBOOK G4 Service source 72 - PowerBook G4 (15-inch Double-Layer SD) Take Apart PC Card Cage 3. Carefully lift up the PC card cage to clear the pin on the eject button. 4. Insert the replacement PC card cage and eject button. Replacement Note: Ensure that the pin on the PC card cage eject button is secured by the hole in the cage mechanism, as shown above. 5. Align the holes in the cage with the screw bosses on the bottom case. 6. Lightly install all four scr (...)

83 Page 83 of Apple POWERBOOK G4 Service source

Apple POWERBOOK G4 Service source PowerBook G4 (15-inch Double-Layer SD) Take Apart - 73 PC Card Cage 7. Reassemble the computer. 8. Testing should include inserting a PC card to check that it can be locked in and that the eject button works smoothly. Check that the speakers work, and that the trackpad and keyboard function properly. Check that the modem and Bluetooth operate. Operate the computer in a darkened room to check for keyboard backlight function. (...)

84 Page 84 of Apple POWERBOOK G4 Service source

POWERBOOK G4 74 - PowerBook G4 (15-inch Double-Layer SD) Take Apart AirPort Extreme w/ Bluetooth AirPort Extreme w/ Bluetooth Tools This procedure requires the following tools: • #0 Phillips 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 • PC card cage (...)

85 Page 85 of Apple POWERBOOK G4 Service source

Apple POWERBOOK G4 Manual PowerBook G4 (15-inch Double-Layer SD) Take Apart - 75 AirPort Extreme w/ Bluetooth Procedure 1. Disconnect the flex cable. 2. Carefully lift off the antenna cables. 3. Remove the two screws. 4. Reassemble the computer. 922-6090 3.2 mm (...)

86 Page 86 of Apple POWERBOOK G4 Service source

Apple POWERBOOK G4 Manual 76 - PowerBook G4 (15-inch Double-Layer SD) Take Apart AirPort Extreme w/ Bluetooth 5. Testing the computer should include using Apple System Profiler to check that the AirPort Extreme card is recognized, test that the AirPort Extreme card is working, insert a PC card to check that it can be locked in and that the eject button works smoothly. Check that both speakers work, and that the trackpad and keyboard function properly. Chec (...)

87 Page 87 of Apple POWERBOOK G4 Service source

Apple POWERBOOK G4 Laptop Manual PowerBook G4 (15-inch Double-Layer SD) Take Apart - 77 Modem Modem Important: • The flex cable routes under the logic board and is secured by adhesive foam. The logic board must be removed to remove or replace the modem flex cable. • There are two insulator washers, one on each side of the modem, on the modem screw nearest the logic board. • A grounding strap on the speaker cable must be captured by the modem screw. Tools Th (...)

88 Page 88 of Apple POWERBOOK G4 Service source

Apple POWERBOOK G4 Service source 78 - PowerBook G4 (15-inch Double-Layer SD) Take Apart Modem Preliminary Steps Before you begin, remove the following: • Battery • Top case • PC card cage Procedure 1. Disconnect the flex. Important: Do not attempt to disconnect it from the logic board. 2. Remove the two screws. Replacement Note: One screw secures a metallic strap attached to the main speaker cable. (...)

89 Page 89 of Apple POWERBOOK G4 Service source

POWERBOOK G4 PowerBook G4 (15-inch Double-Layer SD) Take Apart - 79 Modem Important: The screw nearest the logic board uses two insulator washers. One on the screw (922-7145) and one on the internal frame under the modem. Make sure that these insulators are in place before reinstalling the modem. 3. Disconnect the modem RJ-11 cable from the end of the modem. 4. Install the modem, reassemble the computer and test the modem. (...)

90 Page 90 of Apple POWERBOOK G4 Service source

Apple POWERBOOK G4 Service source 80 - PowerBook G4 (15-inch Double-Layer SD) Take Apart Sound/DC-In Board Sound/DC-In Board Tools This procedure requires the following tools: • #1 Phillips screwdriver (magnetized) • 5 mm socket wrench • Black stick (or other nonconductive nylon or plastic flat-blade tool) Part Location Preliminary Steps Before you begin, remove the following: • Battery • Top case • PC card cage (...)

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Apple POWERBOOK G4 Service source PowerBook G4 (15-inch Double-Layer SD) Take Apart - 81 Sound/DC-In Board Procedure 1. Disconnect the flex connector, speaker wire, power cable, and remove the screw and hexnut screw. 2. Move the board clear of the bottom case port openings, then rotate up. 922-6472 4.5 mm 922-7146 14.2 mm (...)

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Apple POWERBOOK G4 Laptop Manual 82 - PowerBook G4 (15-inch Double-Layer SD) Take Apart Sound/DC-In Board 3. Guide out the DC-in port. 4. Guide out the DC-in port. (...)

93 Page 93 of Apple POWERBOOK G4 Service source

Apple POWERBOOK G4 Service source PowerBook G4 (15-inch Double-Layer SD) Take Apart - 83 Sound/DC-In Board 5. Disconnect the power cable. 6. Slide out the RJ-11 port with cable and transfer it to the replacement board. Note: Pull on the port, or push it with the flat blade of a black stick, until it begins to move, then use the black stick to create leverage behind the port. (...)

94 Page 94 of Apple POWERBOOK G4 Service source

Apple POWERBOOK G4 Manual 84 - PowerBook G4 (15-inch Double-Layer SD) Take Apart Sound/DC-In Board 7. Verify that the rubber block is on the replacement board, or transfer from the replaced board. Replacement Note: Use care during reassembly that the block is not dislodged. 8. Install the replacement sound/DC-in board. Replacement Notes: • Connect the power cable to the sound/DC-in board, and the modem cable to the modem, before installing. • Verify that (...)

95 Page 95 of Apple POWERBOOK G4 Service source

Apple POWERBOOK G4 Manual PowerBook G4 (15-inch Double-Layer SD) Take Apart - 85 Sound/DC-In Board • While tightening the screws, push the board toward the port holes in the bottom case to ensure the DC plug is fully seated into its port. • Verify that the port EMI metal rests above the port plastic. • Verify that the EMI gasket is installed (076-1201). 9. Connect the speaker and flex cables. Note: • Install the “TO MLB” side of the flex cable to (...)

96 Page 96 of Apple POWERBOOK G4 Service source

POWERBOOK G4 86 - PowerBook G4 (15-inch Double-Layer SD) Take Apart Sound/DC-In Board 10. Reassemble and test the computer. 11. Testing should include checking the function of the modem port, DC-in port, the left USB port, and audio ports. (...)

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Apple POWERBOOK G4 Service source PowerBook G4 (15-inch Double-Layer SD) Take Apart - 87 Speaker cable Speaker cable Tools This procedure requires the following tools: • #0 Phillips 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 • PC card cage (...)

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Apple POWERBOOK G4 Manual 88 - PowerBook G4 (15-inch Double-Layer SD) Take Apart Speaker cable Procedure 1. Disconnect the cable where shown and remove one screw attached to the modem. 2. Install the replacement speaker cable. Make sure to capture the metallic strap with the modem screw, and route the cable as shown above. (...)

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POWERBOOK G4 PowerBook G4 (15-inch Double-Layer SD) Take Apart - 89 Logic Board Logic Board Tools This procedure requires the following tools: • #1 Phillips screwdriver (magnetized) • Gasket kit (076-1201) • Black stick (or other nonconductive nylon or plastic flat-blade tool) • Alcohol pads • Thermal Grease (922-7144) Note: Use a tray with divided compartments to organize the screws you remove. Part Location (...)

100 Page 100 of Apple POWERBOOK G4 Service source

Apple POWERBOOK G4 Laptop Manual 90 - PowerBook G4 (15-inch Double-Layer SD) Take Apart Logic Board Preliminary Steps Before you begin, run the computer until warm (if possible) to help soften the thermal material on the logic board, then shut it down and remove the following: • Battery • Top case • PC card cage • Right speaker Note: It may be helpful to remove the optical drive and hard drive to reduce the number of cables to control when replacing the logi (...)

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