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Apple g4 manual

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Table of contents for the manual

  • Page 1

    © 2003 Apple Computer , Inc. All rights reser ved.  Service Source PowerBook G4 (1GHz/867MHz) 5 December 2003[...]

  • Page 2

    © 2002 Apple Computer , Inc. All rights reser ved.  Service Source Take Apart PowerBook G4 (1GHz/867MHz)[...]

  • Page 3

     PowerBook G4 (1GHz/867MHz) Keyboard Replacement Instructions F ollow the instructions in this sheet carefully . F ailure to follow these instructions could damage your equipment and v oid its warr anty . Note: Written and video instr uctions cov ering customer-installable par ts are av ailable at http://www .inf o .apple.com/installpar ts/. W a[...]

  • Page 4

    PowerBook G4 (1GHz/867MHz) Keyboard - 2 4. Close the computer and turn it over . 5. Slide the batter y latch (Figure 1A) to the right to remov e the batter y (Figure 1B) . Removing the battery will prevent you from accidentally turning on the computer. Warning: Removing the battery before shutting down your computer may result in data loss. Figure [...]

  • Page 5

    PowerBook G4 (1GHz/867MHz) Keyboard - 3 9. Release the ke yboard by pulling do wn on the ke yboard release tabs (located to the left of the F1 and F12 ke ys) (Figure 3) , then lift the top por tion of the ke yboard up slightly , and tow ard the display . Figure 3 10. Flip the ke yboard ov er and lay it on the palm rests and tr ackpad. (Figure 4) Fi[...]

  • Page 6

    PowerBook G4 (1GHz/867MHz) Keyboard - 4 11. T ouch the computer’ s inside frame work (a dull gra y conductive composite material) to discharge any static electricity , as sho wn (Figure 5) . Important: To avoid electrostatic discharge damage, always ground yourself by touching the computer’s framework before you touch any parts or install any c[...]

  • Page 7

    PowerBook G4 (1GHz/867MHz) Keyboard - 5 Installing the Replacement K eyboard 1. La y the replacement ke yboard in the correct or ientation ov er the ke yboard opening, then fl ip it toward y ou and la y it face do wn on the palm rests and trackpad to e xpose its connector cable . (Figure 7) Figure 7 2. Firmly inser t the ke yboard cable connector [...]

  • Page 8

    PowerBook G4 (1GHz/867MHz) Keyboard - 6 5. La y the ke yboard fl at into the keyboard opening. 6. Pull down on the k eyboard release tabs while pressing do wn on the top por tion of the ke yboard (Figure 9) . Release the tabs to secure the ke yboard in place. Figure 9 7. Close the displa y and tur n the P owerBook o ver . 8. Replace the batter y .[...]

  • Page 9

    PowerBook G4 (1GHz/867MHz) Keyboard - 7  Apple Computer , Inc. © 2002 Apple Computer , Inc. All r ights reser ved. This document is protected under U .S. Copyright Law and International T reaties, and no par t of this document may be reproduced in an y form without written per mission from Apple. Apple is not responsible f or typographical, pri[...]

  • Page 10

     PowerBook G4 (1GHz/867MHz) Memory Card Replacement Instructions F ollow the instructions in this sheet carefully . F ailure to follow these instructions could damage your equipment and v oid its warr anty . Note: Written and video instr uctions cov ering customer-installable par ts are av ailable at http://www .inf o .apple.com/installpar ts/. [...]

  • Page 11

    PowerBook G4 (1GHz/867MHz) Memory - 2 4. Close the computer and turn it over . 5. Slide the batter y latch (Figure 1A) to the right to remov e the batter y (Figure 1B) . Removing the battery will prevent you from accidentally turning on the computer. Warning: Removing the battery before shutting down your computer may result in data loss. Figure 1 [...]

  • Page 12

    PowerBook G4 (1GHz/867MHz) Memory - 3 9. Release the ke yboard by pulling do wn on the ke yboard release tabs (located to the left of the F1 and F12 ke ys) (Figure 3) , then lift the top por tion of the ke yboard up slightly , and tow ard the display . Figure 3 10. Flip the ke yboard ov er and lay it on the palm rests and tr ackpad. (Figure 4) Figu[...]

  • Page 13

    PowerBook G4 (1GHz/867MHz) Memory - 4 11. T ouch the computer’ s inside frame work (a dull gra y conductive composite material) to discharge any static electricity , as sho wn (Figure 5) . Important: To avoid electrostatic discharge damage, always ground yourself by touching the computer’s framework before you touch any parts or install any com[...]

  • Page 14

    PowerBook G4 (1GHz/867MHz) Memory - 5 Installing the Replacement Memory Card W arning: When handling a memor y car d, do not touc h its gold connectors. Handle the card onl y by the edges. 1. T o install the memor y card, line up the notch in the card with the small tab in the memor y slot. Hold the card at a 30-degree angle (Figure 7A) , and then [...]

  • Page 15

    PowerBook G4 (1GHz/867MHz) Memory - 6 Closing the Computer 1. Flip the ke yboard back to ward the ke yboard opening in the case. 2. Hold the ke yboard at an angle and inser t the tabs on the bottom edge of the ke yboard into the slots below the edge of the k eyboard opening. (Figure 9) Important: Make sure that all the tabs are seated and that the [...]

  • Page 16

    PowerBook G4 (1GHz/867MHz) Memory - 7 6. Replace the batter y . (Figure 11) Important: Make sure that the battery locks securely into place and that the battery latch is slid all the wa y into the lock ed position. Figure 11 7. Reconnect the pow er cord and any other cables that w ere connected, and restar t y our computer . W arning: Never turn on[...]

  • Page 17

     PowerBook G4 (1GHz/867MHz) Bottom Case Replacement Instructions F ollow the instructions in this sheet carefully . F ailure to follow these instructions could damage your equipment and v oid its warr anty . Note: Written and video instr uctions cov ering customer-installable par ts are av ailable at http://www .inf o .apple.com/installpar ts/. [...]

  • Page 18

    PowerBook G4 (1GHz/867MHz) Bottom Case - 2 4. Place a tow el or soft cloth on a table in front of you. (Figure 1A) The towel or cloth will protect the keyboard and display area of the PowerBook when you flip it over to remove the battery and bottom case. Make sure it covers an area large enough for your PowerBook and that it hangs over the edge of [...]

  • Page 19

    PowerBook G4 (1GHz/867MHz) Bottom Case - 3 7. Use a T orx T8 screwdriver to remov e the se ven bottom case scre ws in the order shown. (Figure 3) Important: To avoid damaging the case, be careful that the screwdriver tip does not slip out of the screw head during removal. Figure 3 Note: In the f ollowing two steps y ou will disengage the left and r[...]

  • Page 20

    PowerBook G4 (1GHz/867MHz) Bottom Case - 4 9. Piv ot the bottom case up as shown. (Figure 5) Figure 5 Installing the Replacement Bottom Case 1. T o attach the new bottom case , align the notches on the right and left sides of the case, then press down slightly to secure the case. Check the alignment of the seven screw holes to make sure the bottom [...]

  • Page 21

    PowerBook G4 (1GHz/867MHz) Bottom Case - 5 3. Replace the batter y . (Figure 7) Important: Make sure that the battery locks securely into place and that the batter y latch is slid all the wa y into the lock ed position. Figure 7 4. T ur n the computer ov er . Look at the optical drive slot to mak e sure that the case is properly secured. If a gap e[...]

  • Page 22

    PowerBook G4 (1GHz/867MHz) Bottom Case - 6  Apple Computer , Inc. © 2002 Apple Computer , Inc. All r ights reser ved. This document is protected under U .S. Copyright Law and International T reaties, and no par t of this document may be reproduced in an y form without written per mission from Apple. Apple is not responsible f or typographical, [...]

  • Page 23

     PowerBook G4 (1GHz/867MHz) AirPort Card Replacement Instructions F ollow the instructions in this sheet carefully . F ailure to follow these instructions could damage your equipment and v oid its warr anty . Note: Written and video instr uctions cov ering customer-installable par ts are av ailable at http://www .inf o .apple.com/installpar ts/.[...]

  • Page 24

    PowerBook G4 (1GHz/867MHz) AirPort Card- 2 4. Place a tow el or soft cloth on a table in front of you. (Figure 1A) The towel or cloth will protect the keyboard and display area of the PowerBook when you flip it over to remove the battery and bottom case. Make sure it covers an area large enough for your PowerBook and that it hangs over the edge of [...]

  • Page 25

    PowerBook G4 (1GHz/867MHz) AirPort Card- 3 7. Use a T orx T8 screwdriver to remov e the se ven bottom case scre ws in the order shown. (Figure 3) Important: To avoid damaging the case, be careful that the screwdriver tip does not slip out of the screw head during removal. Figure 3 Note: In the f ollowing two steps y ou will disengage the left and r[...]

  • Page 26

    PowerBook G4 (1GHz/867MHz) AirPort Card- 4 9. Piv ot the bottom case up as shown. (Figure 5) Figure 5 10. T ouch the computer’ s inside frame work (a dull gra y conductive composite material) to discharge any static electricity , as sho wn. (Figure 6) Important: To avoid electrostatic discharge damage, always ground yourself by touching the compu[...]

  • Page 27

    PowerBook G4 (1GHz/867MHz) AirPort Card- 5 Removing the Installed AirP ort Card 1. Pull back on the antenna clip (Figure 7A) to release the antenna cab le connector (Figure 7B) and allow the card to rise up slightly . 2. Pull the card from the AirP or t connector (Figure 7D) . 3. If there is tape securing the antenna cable to the AirP or t Card, ca[...]

  • Page 28

    PowerBook G4 (1GHz/867MHz) AirPort Card- 6 Installing the Replacement AirPort Card 1. If the replacement AirP or t Card came with the AirP or t adapter (Figure 8A) , remov e the metal clip (Figure 8B) and pull the AirP or t Card (Figure 8C) from the adapter . (The adapter and metal clip are not used with your P owerBook.) Figure 8 2. If necessar y [...]

  • Page 29

    PowerBook G4 (1GHz/867MHz) AirPort Card- 7 4. Plug the antenna cable connector (Figure 11A) into the por t on the AirP or t Card, located just below the plastic tab (Figure 11B) . Make sure the connector is str aight bef ore inser ting it into the por t. Note: If tape was removed earlier, use it to secure the antenna cable to the card. 5. Push the [...]

  • Page 30

    PowerBook G4 (1GHz/867MHz) AirPort Card- 8 Closing the Computer 1. T o attach the bottom case, align the notches on the right and left sides of the case, then press down slightly to secure the case. Check the alignment of the seven screw holes to make sure the bottom case is properly positioned. Important: Make sure that the seams between the botto[...]

  • Page 31

    PowerBook G4 (1GHz/867MHz) AirPort Card- 9 3. Replace the batter y . (Figure 13) Important: Make sure that the battery locks securely into place and that the batter y latch is slid all the wa y into the lock ed position. Figure 13 4. T ur n the computer ov er . Look at the optical drive slot to mak e sure that the case is properly secured. If a gap[...]

  • Page 32

    PowerBook G4 (1GHz/867MHz) AirPort Card- 10  Apple Computer , Inc. © 2002 Apple Computer , Inc. All r ights reser ved. This document is protected under U .S. Copyright Law and International T reaties, and no par t of this document may be reproduced in an y form without written per mission from Apple. Apple is not responsible f or typographical,[...]

  • Page 33

     PowerBook G4 (1GHz/867MHz) Hard Drive Replacement Instructions F ollow the instructions in this sheet carefully . F ailure to follow these instructions could damage your equipment and v oid its warr anty . Note: Written and video instr uctions cov ering customer-installable par ts are av ailable at http://www .inf o .apple.com/installpar ts/. W[...]

  • Page 34

    PowerBook G4 (1GHz/867MHz) Hard Drive - 2 4. Place a tow el or soft cloth on a table in front of you. (Figure 1A) The towel or cloth will protect the keyboard and display area of the PowerBook when you flip it over to remove the battery and bottom case. Make sure it covers an area large enough for your PowerBook and that it hangs over the edge of t[...]

  • Page 35

    PowerBook G4 (1GHz/867MHz) Hard Drive - 3 7. Use a T orx T8 screwdriver to remov e the se ven bottom case scre ws in the order shown. (Figure 3) Important: To avoid damaging the case, be careful that the screwdriver tip does not slip out of the screw head during removal. Figure 3 Note: In the f ollowing two steps y ou will disengage the left and r [...]

  • Page 36

    PowerBook G4 (1GHz/867MHz) Hard Drive - 4 9. Piv ot the bottom case up as shown. (Figure 5) Figure 5 10. T ouch the computer’ s inside frame work (a dull gra y conductive composite material) to discharge any static electricity , as sho wn. (Figure 6) Important: To avoid electrostatic discharge damage, always ground yourself by touching the comput[...]

  • Page 37

    PowerBook G4 (1GHz/867MHz) Hard Drive - 5 Removing the Installed Hard Dri ve 1. With your fi ngers , carefully pr y up the hard drive cable connector (Figure 7A) at its sides to disconnect it from the logic board. Y ou may need to pry one side, then the other , in a roc king motion. Figure 7 2. With a T orx T8 screwdriv er , remov e the two screws[...]

  • Page 38

    PowerBook G4 (1GHz/867MHz) Hard Drive - 6 3. Pull up on the right side of the hard dr iv e to remove it. (Figure 9) Important: The hard drive connector cable can be carefully used to help remove the hard drive if it lifts easily. Do not pull hard on the connector cable. Figure 9 Note: There are four rubber stoppers on the hard drive that fit over s[...]

  • Page 39

    PowerBook G4 (1GHz/867MHz) Hard Drive - 7 Installing the Replacement Hard Driv e W arning: T o av oid potential injury or damage, a void touc hing the thin strip of metal that extends up fr om the rib frame at the battery well. Important: A void touching the optical drive as y ou perform this procedure. 1. Make sure that the scre ws (Figure 10A) an[...]

  • Page 40

    PowerBook G4 (1GHz/867MHz) Hard Drive - 8 5. Replace the hard drive mounting brac ket and secure with the scre ws. (Figure 12) Important: Check that the rubber stoppers and Mylar sheath are not pinched by the bracket. Figure 12 6. Connect the hard drive cab le connector (Figure 13) to the logic board. Figure 13[...]

  • Page 41

    PowerBook G4 (1GHz/867MHz) Hard Drive - 9 Closing the Computer 1. T o attach the bottom case, align the notches on the right and left sides of the case, then press down slightly to secure the case. Check the alignment of the seven screw holes to make sure the bottom case is properly positioned. Important: Make sure that the seams between the bottom[...]

  • Page 42

    PowerBook G4 (1GHz/867MHz) Hard Drive - 10 3. Replace the batter y . (Figure 15) Important: Make sure that the battery locks securely into place and that the batter y latch is slid all the wa y into the lock ed position. Figure 15 4. T ur n the computer ov er . Look at the optical drive slot to mak e sure that the case is properly secured. If a gap[...]

  • Page 43

    PowerBook G4 (1GHz/867MHz) Hard Drive - 11 5. Reconnect the pow er cord and any other cables that w ere connected, and restar t y our computer . W arning: Never turn on y our computer unless all of its internal and external parts are in place and it is closed. Operating the computer when it is open or missing parts can damage your computer or cause[...]

  • Page 44

    © 2002 Apple Computer , Inc. All rights reser ved.  PowerBook G4 (1GHz/867MHz) Modem Filter Board Replacement Instructions The f ollowing instructions explain ho w to replace the modem EMI fi lter board in the P ow erBook G4 (1GHz/867MHz) computer . T ools • Black stick (nylon probe tool 922-5065) or other ESD-safe, non-marring tool • Torx[...]

  • Page 45

    PowerBook G4 (1GHz/867MHz) Modem Filter Board - 2 Pr ocedure 1. Disconnect the RJ-11 and the modem wire connectors from the modem fi lter board. 2. Remov e the T orx T8 screw. 3. Guide the modem fi lter board out of the case.[...]

  • Page 46

    © 2002 Apple Computer , Inc. All rights reser ved.  PowerBook G4 (1GHz/867MHz) DC-In Board Replacement Instructions The f ollowing instructions explain ho w to replace the DC-in board in the P owerBook G4 (1GHz/867MHz) computer . T ools • Black stick (nylon probe tool 922-5065) or other ESD-safe, non-marring tool • Torx T6 screwdriver Pr el[...]

  • Page 47

    PowerBook G4 (1GHz/867MHz) DC-In Board - 2 Pr ocedure 1. Disconnect the DC-in board cable connector from the logic board. 2. Remov e the two T orx T6 screws. Note: The screw holding the fan securing tab may be longer than the other. 3. Guide the DC-in board out of the case.[...]

  • Page 48

    PowerBook G4 (1GHz/867MHz) DC-In Board - 3 Replacement Note: If y ou performed a procedure that also remov ed the logic board, ensure that the pow er button cable routes up and left, to ward the center of the top case, under the DC-in board. Replacement Notes: • Install the 1 mm plastic screw shim to the replacement DC-In board.[...]

  • Page 49

    PowerBook G4 (1GHz/867MHz) DC-In Board - 4 • When replacing the DC-in board, ensure that the secondary fan is seated properly over the pin on the rib frame, and with its securing-tab resting on top of the DC-In board. If one screw was longer, replace it through the fan’s securing-tab. • Make sure that the DC connector is straight and centered[...]

  • Page 50

    © 2002 Apple Computer , Inc. All rights reser ved.  PowerBook G4 (1GHz/867MHz) Inverter Board Replacement Instructions The f ollowing instructions explain ho w to replace the inv er ter board in the P owerBook G4 (1GHz/867MHz) computer . T ools • Black stick (nylon probe tool 922-5065) or other ESD-safe, non-marring tool • Torx T6 screwdriv[...]

  • Page 51

    PowerBook G4 (1GHz/867MHz) Inverter Board - 2 Pr ocedure Important: With the bottom case remov ed, be careful if tur ning ov er the computer . Some components could become loose and f all out. 1. Disconnect the inv er ter board fl ex cab le from both the inv er ter board and logic board. 2. Disconnect the bulb wire cab le from the inv er ter board[...]

  • Page 52

    PowerBook G4 (1GHz/867MHz) Inverter Board - 3 4. Install the replacement inv er ter board onto the optical drive. 5. Reassemble and test the computer . Important: Make sure the bottom case is installed correctly. If the slot-load area is slightly bowed, carefully pull the bottom edge of the slot until it clicks into place and becomes flush with the[...]

  • Page 53

    © 2002 Apple Computer , Inc. All rights reser ved.  PowerBook G4 (1GHz/867MHz) Modem Replacement Instructions The f ollowing instructions explain ho w to replace the modem in the P owerBook G4 (1GHz/ 867MHz) computer . T ools • Black stick (nylon probe tool 922-5065) or other ESD-safe, non-marring tool • Torx T6 screwdriver • Torx T8 scre[...]

  • Page 54

    PowerBook G4 (1GHz/867MHz) Modem - 2 Pr ocedure 1. With the displa y open and the ke yboard removed, locate and remo ve the EMI clip that secures the optical drive’ s fl e x cable to the rib frame . Side until reassembling the computer . Replacement Note: When reassembling the computer, ensure that the EMI clip captures the tab on the flex cable[...]

  • Page 55

    PowerBook G4 (1GHz/867MHz) Modem - 3 4. Disconnect the inv er ter board fl ex cab le from the inv er ter board and logic board. 5. Disconnect the optical drive and modem fl e x cables from the logic board. 6. Remov e the two T6 scre ws that secure the modem. 7. Lift up the end of the modem slightly and disconnect the 2-pin cable connector .[...]

  • Page 56

    PowerBook G4 (1GHz/867MHz) Modem - 4 8. Use a thin tool to lift the optical drive slightly , then deroute the modem fl ex cab le. 9. If the modem fl e x cable is not damaged, remov e it and transf er it to the replacement modem. 10. Install the replacement modem. A v oid putting pressure on or stressing the modem board during installation. 11. T [...]

  • Page 57

    PowerBook G4 (1GHz/867MHz) Modem - 5 12. Reassemble and test the computer . Replacement Note: When reinstalling the optical drive, ensure that the bulb wire cable is safely within the case edge so that it will not get pinched by the bottom case. Important: Make sure the bottom case is installed correctly. If the slot-load area is slightly bowed, ca[...]

  • Page 58

    © 2002 Apple Computer , Inc. All rights reser ved.  PowerBook G4 (1GHz/867MHz) DVD-ROM/CD-RW (Combo), DVD-R/CD-RW (Apple SuperDrive) Optical Drive Replacement Instructions The f ollowing instructions explain ho w to replace the combination D VD-R OM/CD-RW optical drive in the P o werBook G4 (1GHz/867MHz) computer . T ools • Black stick (nylon[...]

  • Page 59

    PowerBook G4 (1GHz/867MHz) DVD-R/CD-RW & DVD-ROM/CD-RW Optical Drive - 2 Pr ocedure 1. With the displa y open and the ke yboard removed, locate and remo ve the EMI clip that secures the optical drive’ s fl e x cable to the rib frame . Set it aside f or installation of the replacement drive . Replacement Note: When installing the replacement [...]

  • Page 60

    PowerBook G4 (1GHz/867MHz) DVD-R/CD-RW & DVD-ROM/CD-RW Optical Drive - 3 3. Remov e the two T8 scre ws that secure the hard dr iv e mounting brack et and remov e the brac ket. 4. Disconnect the inv er ter board fl ex cab le from the inv er ter board and logic board. 5. Disconnect the optical drive and modem fl e x cables from the logic board.[...]

  • Page 61

    PowerBook G4 (1GHz/867MHz) DVD-R/CD-RW & DVD-ROM/CD-RW Optical Drive - 4 6. Disconnect the bulb wire cab le from the inv er ter board. 7. Remov e the f our T6 screws that secure the modem and the in ver ter board and remov e the inv er ter board. Replacement Note: When reinstalling the replacement optical drive, ensure that the b ulb wire cable[...]

  • Page 62

    PowerBook G4 (1GHz/867MHz) DVD-R/CD-RW & DVD-ROM/CD-RW Optical Drive - 5 9. Use a thin tool to lift the optical drive slightly , then deroute the modem fl ex cab le. 10. W arning: T o prevent damage to the optical drive, handle the drive only b y the corners. Do not press on the bod y of the drive . To remove the optical drive, pull the drive [...]

  • Page 63

    PowerBook G4 (1GHz/867MHz) DVD-R/CD-RW & DVD-ROM/CD-RW Optical Drive - 6 Peel off the felt strip from the inner top case. If there is any residual adhesive on the top case, rub it away. Apply the new felt strip to the slot-load area. Make sure the new felt strip lies flat. Use a black stick to run the length of the slot to make sure that the fe[...]

  • Page 64

    PowerBook G4 (1GHz/867MHz) DVD-R/CD-RW & DVD-ROM/CD-RW Optical Drive - 7 14. Reassemble and test the computer . Important: Make sure the bottom case is installed correctly. If the slot-load area is slightly bowed, carefully pull the bottom edge of the slot until it clicks into place and becomes flush with the bottom case. Important: Check the o[...]

  • Page 65

    © 2002 Apple Computer , Inc. All rights reser ved.  PowerBook G4 (1GHz/867MHz) Backup Battery Replacement Instructions The f ollowing instructions explain ho w to replace the backup battery in the P owerBook G4 (1GHz/867MHz) computer . T ools • Black stick (nylon probe tool 922-5065) or other ESD-safe, non-marring tool Pr eliminary Steps Bef [...]

  • Page 66

    PowerBook G4 (1GHz/867MHz) Backup Battery - 2 Pr ocedure 1. Disconnect the backup battery cable from the bac kup batter y . Note: If the cable connector gets caught on the ridged area of the top case, use a black stick to raise up the backup battery and then disconnect the cable. 2. Note: The bac kup batter y is compressed between two thin plastic [...]

  • Page 67

    PowerBook G4 (1GHz/867MHz) Backup Battery - 3 3. If there is any adhesiv e left on the surf ace of the inner top case, use a blac k stick to rub it awa y . Do not use solvents . Note: When installing the replacement backup battery, make sure the inner top case is clean and free of debris. 4. P eel off the cov er sheet from the bottom surf ace of th[...]

  • Page 68

    © 2002 Apple Computer , Inc. All rights reser ved.  PowerBook G4 (1GHz/867MHz) Logic Board Replacement Instructions The f ollowing instructions explain ho w to replace the logic board in the P owerBook G4 (1GHz/867MHz) computer . T ools • Torx T8 screwdriver • Black stick (nylon probe tool 922-5065) or other ESD-safe, non-marring tool • R[...]

  • Page 69

    PowerBook G4 (1GHz/867MHz) Logic Board - 2 Pr ocedure 1. With the displa y open and the keyboard remo ved, remo ve the T8 screw near the heat pipe. 2. Disconnect the PC card fl e x cable connector and the ke yed battery connector . Important: If the battery connector has not been disconnected before, the keyed connector may be tight. If necessary,[...]

  • Page 70

    PowerBook G4 (1GHz/867MHz) Logic Board - 3 3. Disconnect the 3-pin backup battery connector from the logic board. 4. Remov e the items listed in Preliminar y Steps, to be remo ved in step 4. Important: With the bottom case removed, be careful when turning over the computer. Some components could become loose and fall out.[...]

  • Page 71

    PowerBook G4 (1GHz/867MHz) Logic Board - 4 5. W arning: The thin cables connected to the L VDS (low v oltage data signal) connector are extremel y delicate . Do not pull or pinch the L VDS cables. Be especially careful when w orking near cables that attach to the displa y . If an y of these cables are damaged, the entire displa y module must be rep[...]

  • Page 72

    PowerBook G4 (1GHz/867MHz) Logic Board - 5 6. At the right side of the logic board, disconnect the 2-pin power b utton cable connector , the DC-in board cable connector , and the inv er ter board and modem fl e x cable connectors. 7. Disconnect the trac kpad, hard dr iv e and optical dr ive fl e x cab le connectors. Note: If tape is covering the [...]

  • Page 73

    PowerBook G4 (1GHz/867MHz) Logic Board - 6 8. Remov e the T8 screw on the edge of the logic board near the battery well. Important: Install this screw first when installing the replacement logic board. This screw helps the logic board align properly to the rib frame. 9. Remov e the T8 screw securing the PC card cage.[...]

  • Page 74

    PowerBook G4 (1GHz/867MHz) Logic Board - 7 10. Remov e the fi ve identical (bronz e colored) T8 screws . Note: When reassembling the computer, do not overtighten the screws.[...]

  • Page 75

    PowerBook G4 (1GHz/867MHz) Logic Board - 8 11. Grasp the logic board near the AirP ort Card carr ier and gently lift the board up , as shown belo w , being careful where it catches on por ts, bac k panel mesh liner , and disconnected cables . If necessary, open the panel door and press on the ports to free the logic board from the back panel. Impor[...]

  • Page 76

    PowerBook G4 (1GHz/867MHz) Logic Board - 9 12. Remov e e xisting memor y cards from the logic board for installation on the replacement logic board. Carefully spread the end br ackets to allo w the card to raise up , then pull out.[...]

  • Page 77

    PowerBook G4 (1GHz/867MHz) Logic Board - 10 13. T ransf er the follo wing from the old logic board to the replacement logic board: • AirPort card carrier • RJ-11 port • U-shaped EMI clip between the FireWire and Ethernet ports[...]

  • Page 78

    PowerBook G4 (1GHz/867MHz) Logic Board - 11 14. Install the f ollowing onto the replacement logic board: • Primary fan • EMI gaskets to the USB ports, FireWire port, DVI-I port, and headphone port, (use an I/O EMI gasket kit)[...]

  • Page 79

    PowerBook G4 (1GHz/867MHz) Logic Board - 12 • Rectangular plastic standoffs around the chips on the underside of the replacement logic board. Note: If openings are present in the standoffs, position them where shown by circles, below. Important: If transfering from the old board, use a razor knife to remove and be very careful not to damage board[...]

  • Page 80

    PowerBook G4 (1GHz/867MHz) Logic Board - 13 • Plastic 1 mm and 1.5 mm washers around the screw holes, shown. Center and press into place.[...]

  • Page 81

    PowerBook G4 (1GHz/867MHz) Logic Board - 14 15. Check that the heat e xchanger has three rectangular thermal interface pads in place . If the pads are missing or damaged, replace the heat e xchanger . 16. Use a raz or blade or blac k stick to gently scr ape awa y any residual thermal transf er material on the heat exchanger on the surf ace that mat[...]

  • Page 82

    PowerBook G4 (1GHz/867MHz) Logic Board - 15 17. Important: If you ha ve remov ed the logic board to access another par t, and you will be placing the original logic board back in the computer , use a b lack stic k to gently scrape a wa y any residual thermal transfer material from the microprocessor chip on the logic board. W arning: When scraping [...]

  • Page 83

    PowerBook G4 (1GHz/867MHz) Logic Board - 16 19. Remov e the new Ethernet label from the area inside the memor y card brack ets, peel off the adhesiv e protector and attach the label, right side up, over the Ethernet ID and bar code on the ID plate inside the batter y well.[...]

  • Page 84

    PowerBook G4 (1GHz/867MHz) Logic Board - 17 20. Install the replacement logic board, and reassemble the computer . Replacement Note: When replacing the logic board, the RJ-11 cable and backup battery wire connectors must be routed, as shown below, so that they do not interfere with the logic board replacement and can later be accessed through the k[...]

  • Page 85

    © 2002 Apple Computer , Inc. All rights reser ved.  PowerBook G4 (1GHz/867MHz) Primary Fan Replacement Instructions The f ollowing instructions explain ho w to replace the pr imar y f an in the P owerBook G4 (1GHz/867MHz) computer . T ools • Black stick (nylon probe tool 922-5065) or other ESD-safe, non-marring tool • Razor blade • Needle[...]

  • Page 86

    PowerBook G4 (1GHz/867MHz) Primary Fan - 2 Pr ocedure 1. With the logic board remov ed from the computer , disconnect the f an connector from the logic board. 2. T ur n ov er the logic board, and locate the cone-shaped pin at the right cor ner of the f an. Pull the rubber pin tight. Use a razor blade to cut through the rubber pin.[...]

  • Page 87

    PowerBook G4 (1GHz/867MHz) Primary Fan - 3 3. T ur n ov er the logic board, then tilt up the fan to remo ve it completely from the logic board. Note: The f an is secured to the logic board by adhesiv e. Rub off any remaining adhesiv e from the logic board. Do not use solvents. Replacement Procedure 1. When installing the replacement f an, if the r [...]

  • Page 88

    © 2002 Apple Computer , Inc. All rights reser ved.  PowerBook G4 (1GHz/867MHz) Secondary Fan Replacement Instructions The f ollowing instructions explain ho w to replace the secondar y fan in the P owerBook G4 (1GHz/867MHz) computer . T ools • Black stick (nylon probe tool 922-5065) or other ESD-safe, non-marring tool • Torx T6 screwdriver [...]

  • Page 89

    PowerBook G4 (1GHz/867MHz) Secondary Fan - 2 Pr ocedure 1. Remov e the T6 screw from the f an brac ket. 2. Disconnect the f an’ s connector from the logic board while removing the logic board. Lift out the f an assembly .[...]

  • Page 90

    © 2002 Apple Computer , Inc. All rights reser ved.  PowerBook G4 (1GHz/867MHz) PC Card Cage Replacement Instructions The f ollowing instructions explain ho w to replace the PC card cage in the P owerBook G4 (1GHz/867MHz) computer . T ools • Torx T8 screwdriver • 4 mm Hex socket or wrench • 5 mm Hex socket or wrench Pr eliminary Steps Bef [...]

  • Page 91

    PowerBook G4 (1GHz/867MHz) PC Card Cage - 2 Pr ocedure 1. Remov e the two scre ws that attach the PC card cage to the r ib frame. (The longer screw is ne xt to the battery connector .) 2. T o remov e the 4 mm hex n ut that secures the PC card cage to the heat exchanger , you ma y want to use a finger to support the 5 mm (magnetic) hex screw underne[...]

  • Page 92

    PowerBook G4 (1GHz/867MHz) PC Card Cage - 3 3. Check that the replacement PC card cage includes a clear plastic shim on the outer frame near the PC card eject b utton. If the shim is not there, tr ansfer the shim from the old PC card cage to the replacement PC card cage. 4. When installing the replacement PC card cage, ensure that the metal fl ang[...]

  • Page 93

    © 2002 Apple Computer , Inc. All rights reser ved.  PowerBook G4 (1GHz/867MHz) Rib Frame and Heat Exchanger Replacement Instructions The f ollowing instructions explain ho w to replace the r ib frame and the heat e xchanger in the P ow erBook G4 (1GHz/867MHz) computer . W arning: Make sure you carefull y follow these instructions, especially wh[...]

  • Page 94

    PowerBook G4 (1GHz/867MHz) Rib Frame and Heat Exchanger - 2 Pr ocedure 1. With the displa y open and the keyboard remo ved, remo ve the fi v e identical T8 screws from the top case. 2. Remov e the items listed in Preliminar y Steps, to be remo ved in step 2. Important: With the bottom case removed, be careful when turning over the computer. Some c[...]

  • Page 95

    PowerBook G4 (1GHz/867MHz) Rib Frame and Heat Exchanger - 3 5. Close the computer to an appro ximate 45-degree angle, and stand it on a soft cloth with the clutch cov ers f acing up. 6. Remov e the f our identical T8 screws from the clutch cov ers (two scre ws on each clutch cov er). 7. Use a blac k stick to pry off the two clutch cov ers. Note: Op[...]

  • Page 96

    PowerBook G4 (1GHz/867MHz) Rib Frame and Heat Exchanger - 4 8. Open the computer so that the displa y rests in your lap and is protected by a soft cloth. 9. W arning: Be especially careful when w orking near cables that attach to the display . If an y of these cables are damaged, the entire display module m ust be replaced. W arning: At the left cl[...]

  • Page 97

    PowerBook G4 (1GHz/867MHz) Rib Frame and Heat Exchanger - 5 10. At the right clutch, note the routing of the inv er ter cable. Without straining the inv er ter cable , gently mov e it aside so you can access the two large silv er-colored screws . 11. Suppor t the display as y ou remov e the two identical, large, silv er-colored T8 screws from the r[...]

  • Page 98

    PowerBook G4 (1GHz/867MHz) Rib Frame and Heat Exchanger - 6 13. Remov e the f our r ib frame scre ws. Three are identical black T8 screws, the f or th is a longer chrome T8 and also secures the heat e xchanger alignment brack et to the end of the heat e xchanger . (Y ou might need to mov e aside the AirP or t antenna cable to reach one of the screw[...]

  • Page 99

    PowerBook G4 (1GHz/867MHz) Rib Frame and Heat Exchanger - 7 15. Disconnect the audio cable at each end of the heat e xchanger .[...]

  • Page 100

    PowerBook G4 (1GHz/867MHz) Rib Frame and Heat Exchanger - 8 16. Piv ot the heat exchanger out of the top case assemb ly . Be careful where it might catch at the L VDS cable. W arning: At the left clutch, the wrapped cable connected to the LVDS connector is extremely delicate. Do not pull or pinch the LVDS cable. W arning: Do not bend the heat pipe.[...]

  • Page 101

    PowerBook G4 (1GHz/867MHz) Rib Frame and Heat Exchanger - 9 17. If replacing the rib frame but reusing the heat e xchanger , scrape off the thermal transf er material residue from the area shown. Apply ne w ther mal transf er mater ial to the logic board chip . Replacement Notes: If replacing the heat e xchanger , transf er the hex n ut and screw t[...]

  • Page 102

    © 2002 Apple Computer , Inc. All rights reser ved.  PowerBook G4 (1GHz/867MHz) Bulb Wire Cable Replacement Instructions The f ollowing instructions explain ho w to replace the bulb wire cab le in the P owerBook G4 (1GHz/867MHz) computer . T ools • Black stick (nylon probe tool 922-5065) or other ESD-safe, non-marring tool • Torx T8 screwdri[...]

  • Page 103

    PowerBook G4 (1GHz/867MHz) Bulb Wire Cable - 2 Pr ocedure Important: With the bottom case remov ed, be careful if tur ning ov er the computer . Some components could become loose and f all out. Note: Remov e any kapton tape as needed and replace during reassembly . 1. Loosen or remov e the chrome T8 screw holding the heat e xchanger alignment brac [...]

  • Page 104

    PowerBook G4 (1GHz/867MHz) Bulb Wire Cable - 3 Replacement Note: After reconnecting the bulb wire , ensure that the bulb wire cab le is saf ely tuck ed within the case edge so that it will not get pinched by the bottom case. 4. Reassemble and test the computer . Important: Make sure the bottom case is installed correctly. If the slot-load area is s[...]

  • Page 105

    © 2002 Apple Computer , Inc. All rights reser ved.  PowerBook G4 (1GHz/867MHz) I/O Door Replacement Instructions The f ollowing instructions explain ho w to replace the I/O door in the P owerBook G4 (1GHz/867MHz) computer . T ools • Black stick (nylon probe tool 922-5065) or other ESD-safe, non-marring tool • Needle nose pliers Pr eliminary[...]

  • Page 106

    PowerBook G4 (1GHz/867MHz) I/O Door - 2 Pr ocedure 1. Using needle nose pliers, pull off the rubber plugs at each end of the door . Remov e the springs, and set aside the plugs and springs. Important: Be very careful not to damage or bend the heat exchanger pipes. 2. Pull the door aw ay from the top case . 3. Remov e the L-shaped pin from each end [...]

  • Page 107

    © 2002 Apple Computer , Inc. All rights reser ved.  PowerBook G4 (1GHz/867MHz) Display Module Replacement Instructions The f ollowing instructions explain ho w to replace the display module on the P owerBook G4 (1GHz/867MHz) computer . W arning: Make sure you carefull y follow these instructions, especially when working near cab les that attach[...]

  • Page 108

    PowerBook G4 (1GHz/867MHz) Display Module - 2 Pr ocedure 1. With the rib frame and heat e xchanger removed, mak e sure • The display is supported on a soft cloth in front of the top case • The display cables are not strained W arning: Be especially careful when w orking near cables that attach to the display . If an y of these cables are damage[...]

  • Page 109

    PowerBook G4 (1GHz/867MHz) Display Module - 3 3. Thread the 2-pin LED sleep cable through the opening in the top case . Carefully guide the LVDS cable through the opening by looping the cable and turning the LVDS connector sideways, as shown, to fit through the opening. 4. At the right clutch, raise the inner clutch mount and disconnect the inv er [...]

  • Page 110

    PowerBook G4 (1GHz/867MHz) Display Module - 4 6. Important: When the replacement display module is installed, and bef ore the clutch cov ers are installed, test that the displa y is seated proper ly . With the computer upr ight and closed, press the computer latch. The display module should pop up slightly if the module is properly seated. 7. Insta[...]

  • Page 111

    © 2002 Apple Computer , Inc. All rights reser ved.  PowerBook G4 (1GHz/867MHz) Top Case Replacement Instructions The f ollowing instructions explain ho w to replace the top case in the P owerBook G4 (1GHz/867MHz) computer . T ools • Black stick (nylon probe tool 922-5065) or other ESD-safe, non-marring tool • Razor blade (optional) Pr elimi[...]

  • Page 112

    PowerBook G4 (1GHz/867MHz) Top Case - 2 Pr ocedure 1. With the preliminar y steps completed, compare the original top case to the replacement top case. 2. Bef ore installing the replacement top case, make sure it includes the f ollowing: • Speaker set and cables • Power button and board (heatstaked to top case) • AirPort antenna cable • Tra[...]

  • Page 113

    PowerBook G4 (1GHz/867MHz) Top Case - 3 4. Con fi r m that the thermal str ip and mesh liners are installed at the back panel. 5. Important: Make sure y ou transfer the bac kup batter y cable from the original top case to the replacement top case. The backup battery cable is tuc ked below the b ulb wire cable along and betw een the speaker and top[...]

  • Page 114

    © 2002 Apple Computer , Inc. All rights reser ved.  Service Source Troubleshooting PowerBook G4 (1GHz/867MHz)[...]

  • Page 115

    PowerBook G4 (1GHz/867MHz) Troubleshooting - 1 Startup Symptom Charts 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. S[...]

  • Page 116

    PowerBook G4 (1GHz/867MHz) Troubleshooting - 2 Startup Symptom Charts 6. With a non-metallic tool, reset the pow er manager by pressing the reset button (located under the ke yboard in the recess just left of the power b utton). W ait fi ve seconds bef ore continuing. Press the po wer button to star t the computer . W arning: Resetting the power m[...]

  • Page 117

    PowerBook G4 (1GHz/867MHz) Troubleshooting - 3 Startup Symptom Charts Flashing question mark appears on the screen 1. Star t up from the software install and restore disc that came with the computer (hold down the "C" k ey during restar t). 2. When the Installer opens, from the Installer men u, select Open Disk Utility . 3. If the hard dr[...]

  • Page 118

    PowerBook G4 (1GHz/867MHz) Troubleshooting - 4 Startup Symptom Charts 4. Make sure system is not o ver heating, the air v ents are clear and unit is not on soft surf ace. 5. Check that the f an cab le is connected and the fan is operational. 6. Check that the heat e xchanger is properly attached to the processor . Important: If the heat exchanger i[...]

  • Page 119

    PowerBook G4 (1GHz/867MHz) Troubleshooting - 5 Error Beeps Symptom Charts At startup, a dialog box comes up stating: “ker nel panic” in Mac OS X or “Built-in memory test has detected an error” in Mac OS 9 1. If there are two RAM cards installed in the e xpansion slots, remo ve top card and restar t. • If symptom repeats, replace bottom ca[...]

  • Page 120

    PowerBook G4 (1GHz/867MHz) Troubleshooting - 6 AirPort Card Symptom Charts 3. If a RAM card is not installed in the upper e xpansion slot, replace RAM in lower RAM slot with known-good and compatib le RAM card and restar t. • If symptom repeats, replace logic board. Computer beeps f our times at startup 1. F our beeps indicates a bad checksum f o[...]

  • Page 121

    PowerBook G4 (1GHz/867MHz) Troubleshooting - 7 Battery Symptom Charts The battery won't charge 1. Remov e any e xter nally connected peripherals. 2. T r y known-good pow er outlet. 3. Connect known-good P owerBook (1GHz/867MHz) pow er adapter (661-1798) and pow er cord or plug; make sure the DC plug is fi rmly inser ted. The DC plug should li[...]

  • Page 122

    PowerBook G4 (1GHz/867MHz) Troubleshooting - 8 Battery Symptom Charts Display Display latch not working Note: When the displa y is being closed, a latch hook in the top of the display housing should be magnetically pulled down through the slot in the top case and secured b y the latch mechanism. When the latch b utton is pushed, the hook should rel[...]

  • Page 123

    PowerBook G4 (1GHz/867MHz) Troubleshooting - 9 Battery Symptom Charts 5. If the number of subpix el anomalies is acceptable , explain to the customer that the pix el anomalies are within speci fi cations, and no repair is necessar y . Important: Do not release the speci fi cations to customers. Instead, inform them that a cer tain number of subpi[...]

  • Page 124

    PowerBook G4 (1GHz/867MHz) Troubleshooting - 10 Hard Drive Symptom Charts Hard Driv e Internal hard dri ve will not initialize If in Mac OS X: 1. Star t up from the software install and restore disc that came with the computer (hold down the "C" k ey during restar t). 2. When the Installer opens, from the Installer men u, select Open Disk[...]

  • Page 125

    PowerBook G4 (1GHz/867MHz) Troubleshooting - 11 Modem Symptom Charts Modem No modem dial tone 1. Check that the correct modem is selected. In Mac OS X, check Network Setup . In Mac OS 9, check the Modem control panel. 2. V erify known-good analog (not digital) telephone line. 3. V erify known-good RJ11 telephone cable . 4. V erify RJ11 cable is not[...]

  • Page 126

    PowerBook G4 (1GHz/867MHz) Troubleshooting - 12 PC Card Symptom Charts The disc icon does not show up on desktop, or a dialog box appears to initialize disc, when inserting a read-only disc 1. V erify the correct type of disc is being used. 2. Note: Some brands of 24x or 32x CD-R media ma y not work with the SuperDrive. T r y a different br and or [...]

  • Page 127

    PowerBook G4 (1GHz/867MHz) Troubleshooting - 13 Ports Symptom Charts P orts The FireW ire or USB port is not r ecognizing devices 1. Completely shut down, then press the po wer button to start the computer . 2. Use Software Update in Mac OS X system pref erences (or the Software Update control panel in Mac OS 9) to v er ify that the latest software[...]

  • Page 128

    PowerBook G4 (1GHz/867MHz) Troubleshooting - 14 Sound Symptom Charts Sound No sound heard and the Speakers section of the Sound contr ol panel indicates that an external de vice is plugged in (to the headphone jack or USB ports) 1. If there is nothing plugged into the headphone jack or USB ports, the picture in the Speakers section of the Sound con[...]

  • Page 129

    PowerBook G4 (1GHz/867MHz) Troubleshooting - 15 Video Symptom Charts 7. Reset PRAM (Press the pow er button, then hold down the Option-Command-P-R ke ys until you hear the startup chime at least one additional time after the initial star tup chime). W arning: Resetting the PRAM will permanently remo ve a RAM disk, if present, and all of its content[...]

  • Page 130

    PowerBook G4 (1GHz/867MHz) Troubleshooting - 16 Misc. Symptoms Symptom Charts 7. Replace inv er ter board. 8. Replace displa y assembly . 9. Replace logic board. Computer appears to work, b ut no video on external de vice connected to the TV out port (S-video out port) 1. The de vice must be connected to the S-video por t while the P owerBook is sl[...]

  • Page 131

    PowerBook G4 (1GHz/867MHz) Troubleshooting - 17 Misc. Symptoms Symptom Charts The Date and Time settings r eset all the time Note: Resetting the power manager or PRAM resets the date and time. 1. Do a backup battery test: • Set the date and time. • Perform a Shut Down from the Apple menu or Special menu. • Remove the main battery and disconne[...]

  • Page 132

    PowerBook G4 (1GHz/867MHz) Troubleshooting - 18 Misc. Symptoms Symptom Charts 5. If no sound as well as microphone is not working, v er ify cable connections . 6. Replace top case. During startup boot sequence and bef ore r eaching Finder , the f ollowing dialog box appears: “The built-in memory test has detected an err or” 1. If a RAM card is [...]

  • Page 133

    © 2002 Apple Computer , Inc. All rights reser ved. This sheet shows the scre ws used in the P o werBook G4 (1GHz/867MHz) computer  and indicates the replacement procedure where first remov ed.  T o see where the screws are located in the computer , refer to the  "P o werBook G4 (1GHz/867MHz) Screw Locator ." T orx T8, 8 mm long:[...]

  • Page 134

    © 2002 Apple Computer , Inc. All rights reser ved. One T orx T8, 4.5 mm long T wo identical T orx T8, 9.3 mm long Modem Filter Board Se ven identical T orx T8, 8 mm long Bottom Case F our identical (blac k) T orx T8, 4.9 mm long Hard Drive and Optical Drive Hold Do wn Brac ket Hard Drive  PowerBook G4 (1GHz/867MHz) Scr ew Locator[...]

  • Page 135

    PowerBook G4 (1GHz/867MHz) Screw Locator - 2 Secondar y F an One T orx T6, 5.12 mm long DC-In Board One T orx T6, 4.15 mm long In ver ter Board T wo T orx T6, 4.15 mm long Modem T wo T orx T6, 4.15 mm long 269 (A) - One T orx T6, 5.12 mm long A[...]

  • Page 136

    PowerBook G4 (1GHz/867MHz) Screw Locator - 3  Logic Board One T orx T8, 4.5 mm long (A) - One T orx T8, 5 mm long (B) - One T orx T8, 5.2 mm long Three T orx T8, 4.5 mm long Fiv e identical T orx T8,  6.4 mm long (bronze) A B[...]

  • Page 137

    PowerBook G4 (1GHz/867MHz) Screw Locator - 4  Rib F rame and Heat Exchanger PC Card Cage F our identical T orx T8, 5.2 mm long (C) - One 4 mm He x Nut One 5 mm He x Screw , magnetic, (accessed from k eyboard opening) (B) - One T orx T8, 6.5 mm long (A) - One T orx T8, 5.2 mm long Fiv e identical T orx T8, 4.4 mm long  A C B (B) - One T [...]

  • Page 138

    PowerBook G4 (1GHz/867MHz) Screw Locator - 5 Three identical (Black)  T orx T8, 9.5 mm long (A) - One (Chrome) T orx T8,  10 mm long T wo identical T orx T8, 16.75 mm long Rib F rame and Heat Exchanger (continued) A[...]

  • Page 139

    © 2002 Apple Computer , Inc. All rights reser ved. Hard Drive Screw 922-4502 Hard Drive Rubber Stopper Hard Drive Fle x Cable 922-4378 Bottom Case 922-5443 Battery 661-2740 Hard Drive Mounting Brac ket 076-0946 Hard Drive 661-1801 (40 GB)  661-1802 (60 GB) CD-RW/D VD-ROM (Combo) Drive  661-2690 D VD-R/CD-R W (Apple SuperDrive)[...]