Notebook Subassembly Removal and Replacement Procedures

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The following paragraphs contain field service-level removal/replacement procedures for the Notebook.

Caution: Prior to removing any of the internal FRUs in the notebook, remove the AC Adapter, battery, floppy and hard drives and all external options installed on the notebook.

6.5.1 Removing/Replacing the Notebook Battery Pack

The procedure for removing and replacing the battery pack(s) is as follows:

  1. Turn off the computer.
  2. Locate the battery door (right side of notebook near the front) (see Figure 6-3). Press the battery door inwards and slide the door toward the front of the notebook; remove the battery door.
  3. Grasp the ribbon loop on the battery and pull the battery out of the compartment..
  4. When replacing the battery, insert the end opposite the ribbon loop with the battery notches pointing upwards. Slide the battery into the compartment and replace the battery door.

Hard Drive Assembly

Assembly Bottom View

Figure 6-3 Removing Battery and Disk Drives

6.5.2 Removing/Replacing PCMCIA Options

The procedure for removing and replacing the PCMCIA options is as follows:

  1. Turn off the computer.
  2. Remove the PCMCIA device(s).
  3. To replace the PCMCIA Device, open the cover door and insert the device. Reinstall any external cabling required for the device.
  4. 5.3 Removing/Replacing the Floppy Drive

To remove and replace the Floppy Drive, perform the following procedure:

  1. Remove the battery as described in Paragraph 6.5.1 above.
  2. Turn the notebook over so that the bottom is facing up and the floppy drive is on the right side. Lay the notebook on a padded, flat work surface.
  3. Locate the Floppy Release Button near the center of the notebook (Figure 6-3).

Caution: When removing the Floppy Drive Assembly, grasp it by its sides; otherwise damage to the floppy drive can occur.

  1. Push the Floppy Release Button toward the front of the notebook and simultaneously pull outwards on the floppy drive by placing your thumb over the ribbed outer edge of the floppy drive assembly. When the floppy drive is released, grasp the assembly by the two sides and remove the assembly from the notebook.
  2. The Floppy Drive Assembly can be further disassembled by removing the Phillips-head screws from the sides of the floppy drive assembly; lifting off the cover and lifting out the floppy drive and cable connector (ZIF Connector type). Unplug the cable at the ZIF Connector .

Note: When reassembling the floppy drive, it's easier to install the shield on the floppy drive before installing the drive into the plastic housing.

6.5.4 Removing/Replacing the Hard Drive

The procedure for removing and replacing the Hard Drive assembly is as follows: 1.

Power down the notebook, remove the battery packs, and disconnect the AC Adapter, if installed.

Disconnect any peripheral device interface cables from the external interface connectors and remove any installed PCMCIA options.

  1. Turn the computer over so that the Hard Drive panel is on your right side (See Figure 6-3). Press down on the circular bump with your thumb to release the hard drive cover; remove the cover and lay aside for later reinstallation.
  2. Using finger pressure, slide the metal cover downwards toward the edge of the notebook; then lift upwards to remove the metal cover.
  3. Insert a small blade straight slot screwdriver into the recess in the plastics and gently lift the frontmost edge of the drive out of the bay.
  4. Lay the hard drive on its back.Then using a small straight slot screw driver, gently pry on each end of the connector on the Disk Drive and rock it back and forth until the connector is removed from the drive assembly.
  5. Replacement is essentially the reverse of steps 1 through 6.
  6. 5.5 Removing/Replacing the Keyboard Assembly

The procedure for removing and replacing the keyboard assembly is as follows:

  1. Turn off the computer and disconnect the ac power adapter (if it is attached).
  2. The top edge of the keyboard is held in place by plastic tabs beneath the CTRL and Right Arrow Keys. Pull the tabs toward the front of the notebook (tabs snap into an 1/8 inch recess in the plastics).
  3. Using a small straight-blade screwdriver, lift the front edge of the keyboard upwards.
  4. Lift the front edge of the keyboard slightly and gently pull the keyboard towards the front of the notebook exposing two cables that connect the keyboard to the main board.
  5. Release the two ZIF (zero insertion force ) connectors using a plastic stick or other nonmetallic object and remove the cables from the main board connectors
  6. Remove the keyboard assembly from the notebook.
  7. When installing the replacement keyboard, essentially reverse the above procedures.
  8. 5.6 Removing/Replacing the Heat Sink

To remove and replace the heat sink, perform the following procedure:

  1. Remove the keyboard assembly as described in paragraph 6.5.5.
  2. Remove the two Phillips-head screws that secure the heatsink to the main board (note that one of the screws is located near the HDD connector).
  3. Lift upwards on the heatsink and remove it from the base.
  4. Replacement is the reverse of steps 1 through 3 above.
  5. 5.7 Removing/Replacing Dual Inline Memory Modules (DIMMS)

To remove and replace the expansion memory, use the following procedure:

1 . Loosen the keyboard assembly (but do not disconnect keyboard cables) as described in steps 1 through 5 of Paragraph 6.5.5).

  1. Remove the Heatsink as described in Paragraph 6.5.6.
  2. Using the back edge of the keyboard as a hinge, lift the front edge of the keyboard up and lay it against the LCD assembly.
  3. Push the two metal springs away from the board edge and remove the DIMMS board.
  4. When installing a DIMMS board, insert the edge of the board into the rear of its connector using a slight rocking motion at an angle to the surface of the board.
  5. Once the DIMM is fully inserted in the connector, push downwards on both sides of the board to snap it in place.
Figure 6-4 Removing/Replacing Expansion RAM

6.5.8 Removing and Replacing the Cover-Display Assembly

To remove the cover-display assembly, perform the following procedure:

  1. Remove the keyboard and heatsink as described in paragraphs 6.5.5 and 6.5.6 respectively.
  2. Remove the cable cover below the display by lifting upwards on the front edge of the cover.
  3. Unplug the video cable that mates with the Main Board.
  4. With the main video cable out of the way, two smaller cables are visible. Unplug the rightmost cable.
  5. Using a plastic stick, slide the right and left hinge covers away from the base assembly.
  6. Lay the display completely back and remove the four screws that secure the display hinges to the base case assembly.
  7. Ensure that the display cables are free from the top case assembly and remove the display assembly.
  8. Reinstallation of the Display Assembly is the reverse of steps 1 through 8 above.
  9. 5.9 Removing and Replacing the Inverter Board

To remove and replace the Inverter Board assembly, perform the following procedure:

Caution: If the notebook is powered up with the LCD bezel removed, you can be exposed to high voltages which could result in shock and equipment damage. Ensure that the batteries and AC adapter are removed from the notebook when working on the LCD/Display assembly.

1 . Use a narrow piece of plastic or pointed tweezers to apply light pressure to one edge of the lower screw covers. The lower screw covers will bow outwards and can be removed.

  1. Remove the rubber upper screw covers using a pair of tweezers.
  2. Remove the six screws that secure the bezel to the display assembly (a small Phillips-head screwdriver is recommended for removing the two screws at the top of the bezel).
  3. Pull on the inside edges of the bezel; remove bezel and lay aside for later reinstallation.
  4. Peel back the EMI shield along the right side of the display to expose the Inverter Board.
  5. Disconnect the connectors at the top and bottom of the Inverter Board.
  6. Use the small Phillips-head screwdriver to remove the two screws holding the Inverter Board; remove the Inverter Board Assembly.
  7. Reinstallation of the Inverter Board is the reverse of steps 1 through 7 above.
  8. 5.10 Opening/Replacing the Top Case Assembly

To remove/replace the Top Case Assembly, perform the following procedure:

1 . Remove the Keyboard Assembly and Heat Sink Assembly as described in Paragraphs 5.5.5 and 5.5.6.

  1. Remove the four screws that secure the Top Case Assembly to the base. Note that the screw at the rear of the opening is shorter than the remaining three screws.
  2. Using a plastic stick, unlock the ZIF connector located near the glide pad and remove the cable from the connector.
  3. Remove the cable cover below the display by lifting upwards on the front edge of the cover.
  4. Turn the notebook over and remove the six Phillips-head screws from the bottom of the notebook.
  5. Rotate the notebook so that the rear of the unit is facing you; remove the rear door assembly by bowing it outwards.
  6. Several recesses are located just above the two rear connectors. Use a small flat-blade screwdriver to disengage the snaps associated with the right and left recesses.
  7. Lift and push the Display Assembly forward to disengage it from the Base Assembly.
  8. Replacement of the Top Case Assembly is the reverse of steps 1 through 8 above.
  9. 5.11 Removing/Replacing the Touch Pad Assembly

To remove and replace the Touch Pad Assembly, perform the following procedure:

1 . Remove the Top Case Assembly as described in the previous paragraph.

  1. Turn the Top Case Assembly over and remove the four screws that secure a metal shield to the plastics.
  2. Lift the plastic frame that rests on top of the touch pad.
  3. Unplug the flex cable from the connector on the touch pad. Note that the board connector is a LIF (Low insertion force) type; the cable is held in place by friction.
  4. Slide the board assembly to the right and remove from the unit.
  5. Replacement of the Touch Pad Board Assembly is essentially the reverse of Steps 1 through 5 above.
  • T) Remove Top Case Assembly
  • 2) Remove four screws holding metal shield
  • 3) Lift plastic frame that rests on top
  • 4) Unplug LIF Cable Connector
  • 5) Remove Board Assembly

Touch Pad Assembly

  • 2) Remove four screws holding metal shield
  • 3) Lift plastic frame that rests on top
  • 4) Unplug LIF Cable Connector
  • 5) Remove Board Assembly

Touch Pad Assembly

Figure 6-5 Touchpad Removal/Replacement

6.5.12 Removing/Replacing the SIR Board

To remove and replace the SIR Board, perform the following procedure:

  1. Remove the Top Case Assembly as described in paragraph 6.5.10.
  2. Unplug the SIR Board cable connector from the Main Board (small leftmost cable connector at J8 as shown in Figure 6-6).
  3. Remove the SIR Board from the notebook.

4 Replacement is essentially the reverse of steps 1 through 3 above.

(Ï) Remove Top Case Assembly

Sound Isolation Window

Figure 6-6 SIR Board Removal/Replacement

6.5.13 Removing/Replacing the Primary Battery Board

To remove and replace the Primary Battery Board, perform the following procedure:

  1. Remove the Top Case Assembly as described in paragraph 6.5.10.
  2. Disconnect the cable located next to the HDD Connector.
  3. Remove the two screws that secure the board to the plastics and remove the board.
  4. Replacement is essentially the reverse of steps 1 through 3 above.

Note: When reinstalling the Primary Battery Board, use the battery pack as a guide to ensure that the connector slots properly align with the battery slots.

  • T) Remove Top Case Assembly
  • Unplug the Cable Connector from J13
  • 3) Remove two screws and lift Board Out of unit
The Count Coffin

Primary Battery Board

Figure 6-7 Primary Battery Board Replacement

6.5.14 Removing/Replacing the Power Supply Board Assembly

To remove and replace the Power Supply Board Assembly, perform the following procedure:

  1. Remove the Top Case Assembly as described in paragraph 6.5.10.
  2. Remove the metal shield that covers the Power Supply Board.
  3. Using a plastic stick, lift up on the end of the board that is adjacent to the processor. The board assembly snaps out. Remove board from unit.
  4. Replacement is essentially the reverse of steps 1 through 3 above.

(?) Remove Top Case Assembly (2) Remove metal shield

Figure 6-8 Power Supply Board Removal

6.5.15 Removing/Replacing the Memory Board

To remove and replace the Memory Board Assembly, perform the following procedure:

  1. Remove the AC Adapter, Battery Pack, Hard Disk Drive and Floppy Disk Drive from the unit.
  2. Remove the Top Case Assembly as described in Paragraph 6.5.10.
  3. Using a plastic stick, lift up on the left and right edges of the board. The board assembly snaps out. Lift the board out of the unit.
  4. Reassembly is the reverse of steps 1 through 3 above.
  • 7) Remove Top Case Assembly
  • 2) Free connectors by lifting up on left and right edges of board Remove Board Assembly

Figure 6-9 Memory Board Removal

6.5.16 Removing/Replacing the Main Board

To remove and replace the Main Board Assembly, perform the following procedure:

  1. Remove the AC Adapter, Battery Pack, Hard Disk Drive and Floppy Disk Drive from the unit.
  2. Remove the keyboard assembly as described in Paragraph 6.5.5
  3. Remove the Heatsink as described in paragraph 6.5.6.
  4. Remove the Power Supply Board as described in paragraph 6.5.14.
  5. Remove the Memory Board as described in paragraph 6.5.15.

6 Disconnect all interboard cable connectors (SIR Board Connector from J9; Primary Battery Board Connector from J15, etc.

7 Using a small flat blade screwdriver and apply light pressure in a rocking motion to remove the hard drive cable connector.

8 Remove the three large Phillips-head screws (one near the 25-pin parallel port and two screws near the floppy connector. Do not remove the smaller

Phillips-head screws as they are part of the PCMCIA connector hardware.

  1. Using a 5 mm hex driver, remove the hex nut adjacent to the display cable connectors.
  2. Lift up along the front edge of the Main Board Assembly until it clears the hard drive cavity; then pull the board forward and out of the plastics.
  3. Remove the secondary Battery and transfer to the replacement Main Board (reference Paragraph 6.5.17).

12 Reassembly is essentially the reverse of steps 1 through 10 above.

  • 7) Remove Battery, HDD, and Floppy Drive and Top Case Assembly
  • 2) Remove the Memory and Battery Boards.
  • 3) Remove HDD, Primary Battery Board, and SIR Board Connectors
  • i) Removethree Phillips screws and hex nut

Figure 6-10 Main Board Removal/Replacement

6.5.17 Removing/Replacing the Secondary Battery Board

To remove and replace the Secondary Battery Assembly, perform the following procedure:

  1. Remove the Main Board Assembly as described in paragraph 6.5.16.
  2. Carefully slide the secondary Battery Board Assembly from its right angle connector and remove board from unit.
  3. Replacement is the reverse of steps 1 and 2 above.
  • Remove Battery, HDD, and Floppy Drive and Top Case Assembly (?) Remove the Main Board.
  • 3^) Carefully slide the Secondary Battery Board from its right-angleConnector

Figure 6-11 Secondary Battery Board

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