Apple IMAC FLAT PANEL Service Manual

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Service Source

iMac (Flat Panel)

Updated 22 March 2005

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iMac (Flat Panel)

Power Mac G4 - 1

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Service Source

Take Apart

iMac (Flat Panel)

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Tools

The following tools are recommended for the take apart procedures.

• service repair kit (076-0900) includes:

– the service stand (076-0898) – diagnostic cables (076-0897)

• thermal paste (922-4757)

torque driver (076-0899)

•

• 1.5 mm hex driver (for LCD bezel screws)

• phillips #0 screwdriver)

• torx screwdriver set (6, 8, 10, 15, 25)

• plastic flatblade screwdriver or stylus

• needlenose pliers

• ESD wriststrap and mat

Service Stand

Tools

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1. Support the computer by neck and the base (A). Gently position the computer in the service stand with the ﬂat panel facing up (B).

2. Note: The base of the computer can be rotated when servicing internal parts.

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Tools

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User Access Plate

Tools

This procedure requires the following tools:

• Phillips #0 screwdriver

Part Location

User Access Plate

Preliminary Steps

Before you begin, do the following:

• Position the computer in the service stand.

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Procedure

1. Loosen the four captive screws on the access panel.

2. Remove the panel by grabbing onto two captive screws and lift the panel off the base.

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User Access Plate

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AirPort Card

Tools

This procedure requires no tools.

Part Location

AirPort Card

Preliminary Steps

Before you begin, do the following:

• Position the computer in the service stand.

• Remove the user access plate.

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Procedure

1. Unplug all cables from the computer except the power cord.

2. Important: To avoid electrostatic discharge, always ground yourself by touching metal before you touch any parts or install any components inside the computer. To avoid static electricity building back up in your body, do not walk around the room until you have completed the installation and closed the computer.

3. Touch a metal surface inside the computer to ground yourself.

4. Unplug the power cord.

5. Disconnect the AirPort antenna and pull the plastic tab to remove the card from the slot.

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AirPort Card

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Memory, SO-DIMM (userinstallable)

Tools

No tools are required for this procedure.

Part Location

Note: The user-installable memory slot is identiﬁed as Slot J12 by Apple Hardware Test and Apple System Proﬁler.

Preliminary Steps

Before you begin, do the following:

• Position the computer in the service stand.

• Remove the user access plate.

Note: There are two RAM expansion slots on the computer. One slot (top of the logic board) accepts the factory-installed standard PC-133 168-pin DIMM. The other slot (bottom of logic board) accepts a standard PC-133 144-pin SO-DIMM and is accessible on the bottom of the computer. Only the SO-DIMM slot is accessible by the user.

Memory, SO-DIMM (user-installable)

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Procedure

1. Unplug all cables from the computer except the power cord.

3. Touch a metal surface inside the computer to ground yourself.

4. Unplug the power cord.

5. Push the tabs outward to release the memory.

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Memory, SO-DIMM (user-installable)

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6. Remove the memory from the slot.

Memory, SO-DIMM (user-installable)

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Bottom Housing

Tools

This procedure requires the following tools:

• Torx-15 screwdriver

Part Location

Preliminary Steps

Before you begin, do the following:

• Position the computer in the service stand.

• Remove the user access plate.

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Bottom Housing

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Procedure

1. Remove the four torx screws.

Replacement Note:

you do not have a torque driver, you will have to make sure these screws are tightened by hand FIRMLY, BUT NOT FORCIBLY. Or, purchase the service tool (076-0899) in order to ensure the thermal pipe is firmly mated with the top base. If the bottom housing is not securely attached to the base in this fashion, the CPU may overheat and become damaged.

Application’” in this chapter.Rotate the base so that the optical drive door is on the right.

These torx screws must be tightened to at least 17 in.-lbs. If

For more information, refer to “Thermal Paste

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2. Rotate the base so the optical drive door is on the right. Gently open the bottom housing in the direction of the arrow. Note: Cables are still attached to the logic board.

Important: Diagnostic service cables allow the unit to run while the bottom housing is

open (as shown above). However, the computer cannot run for more than ﬁve minutes with the bottom housing open. If it is open longer, the CPU may overheat and become damaged.

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3. Disconnect the following:

Power supply connector

Hard drive/optical drive data cable

C AC line filter connector

D AirPort antenna connector

E Plastic cable retainer and video cable

F Grounding screw

Note: View the document at a larger size to enlarge this graphic.

4. Set the bottom housing aside.

Warning: Whenever the bottom housing is opened for service, you must do two things:

1.You must clean the original thermal film from the surfaces joining the thermal interface layer and reapply thermal paste to the thermal pipe.

2.You must tighten the four torx screws on the bottom housing to a minimum of

17 in.-lbs. If you do not have a torque driver, you will have to make sure these screws are tightened by hand FIRMLY, BUT NOT FORCIBLY. Or, purchase the service tool (076-0899) in order to ensure the thermal pipe is firmly mated with the top base. If the bottom housing is not securely attached to the base in this fashion, the CPU may overheat and become damaged.

follow either of these steps could cause the computer to overheat and damage internal components.

Refer to the topic, “Thermal Paste Application” for detailed information.

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Failure to

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Thermal Paste Application

Tools

This procedure requires the following tools:

• Plastic stylus or plastic spatula to remove the old thermal paste

• Plastic stylus or plastic spatula to spread the thermal paste

• Thermal paste (922-4757)

Part Location

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Thermal Paste Application

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Procedure

1. Thoroughly clean the original thermal ﬁlm from the mating surfaces (circled below) of the bottom housing and thermal pipe. Use a plastic stylus to scrape the surfaces clean. Note: Do not use an abrasive material or liquid cleaner.

2. Squeeze a thin ﬁlm of thermal paste onto the thermal pipe. Spread the paste evenly.

3. Replace the bottom housing. Warning:

that must be tightened to at least 17 in.-lbs. If you do not have a torque driver, you will have to make sure these screws are tightened by hand FIRMLY, BUT NOT FORCIBLY. Or, purchase the service tool (076-0899) in order to ensure the thermal pipe is firmly mated with the top base. If the bottom housing is not securely attached to the base in this fashion, the CPU may overheat and become damaged.

Important: Diagnostic service cables allow the unit to run while the bottom housing is

open (as shown above). However, the computer cannot run for more than ﬁve minutes with the bottom housing open. If it is open longer, the CPU may overheat and become damaged.

Thermal Paste Application

The bottom housing has four torx screws

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RJ-11 Modem Filter Board

Tools

This procedure requires the following tools:

• Torx-6 screwdriver

Part Location

Preliminary Steps

Before you begin, do the following:

• Position the computer in the service stand.

• Remove the user access plate.

• Remove the bottom housing.

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RJ-11 Modem Filter Board

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Procedure

1. Remove two screws and disconnect the cable from the modem.

2. Remove the RJ-11 board from the I/O port.

Warning: Whenever the bottom housing is opened for service, you must do two things:

1. You must clean the original thermal film from the surfaces joining the thermal interface layer and reapply thermal paste to the thermal pipe.

2. You must tighten the four torx screws on the bottom housing to a minimum of

follow either of these steps could cause the computer to overheat and damage internal components.

Refer to the topic, “Thermal Paste Application” for detailed information.

Failure to

RJ-11 Modem Filter Board

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Modem

Tools

This procedure requires the following tools:

• Torx-8 screwdriver

Part Location

Preliminary Steps

Before you begin, do the following:

• Position the computer in the service stand.

• Remove the user access plate.

• Remove the bottom housing.

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RJ-11 Modem Filter Board

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Procedure

1. Remove two screws and disconnect the cable.

2. Lift the modem from the connector on the logic board.

Warning: Whenever the bottom housing is opened for service, you must do two things:

1. You must clean the original thermal film from the surfaces joining the thermal interface layer and reapply thermal paste to the thermal pipe.

2.You must tighten the four torx screws on the bottom housing to a minimum of

follow either of these steps could cause the computer to overheat and damage internal components.

Refer to the topic, “Thermal Paste Application” for detailed information.

Failure to

RJ-11 Modem Filter Board

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Memory (factory-installed)

Tools

This procedure requires the following tools:

• No tools are required

Part Location

Note: The factory-installed memory slot is identiﬁed as Slot J13 by Apple Hardware Test and Apple System Proﬁler.

Preliminary Steps

Before you begin, do the following:

• Position the computer in the service stand.

• Remove the user access plate.

• Remove the bottom housing.

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Memory (factory-installed)

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Procedure

1. Push down on the ejector tabs to release the memory module.

2. Pull the memory up and out of the slot.

Warning: Whenever the bottom housing is opened for service, you must do two things:

1. You must clean the original thermal film from the surfaces joining the thermal interface layer and reapply thermal paste to the thermal pipe.

2.You must tighten the four torx screws on the bottom housing to a minimum of 17 in.-lbs. If you do not have a torque driver, you will have to make sure these screws are tightened by hand FIRMLY, BUT NOT FORCIBLY. Or, purchase the service tool (076-0899) in order to ensure the thermal pipe is firmly mated with the top base. If the bottom housing is not securely attached to the base in this fashion, the CPU may overheat and become damaged. Failure to follow either of these steps could cause the computer to overheat and damage internal components.

Refer to the topic, “Thermal Paste Application” for detailed information.

Memory (factory-installed)

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Battery

Tools

This procedure requires the following tools:

• No tools are required

Part Location

Preliminary Steps

Before you begin, do the following:

• Position the computer in the service stand.

• Remove the user access plate.

• Remove the bottom housing.

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Battery

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Procedure

1. Using a ﬂatblade screwdriver, gently pry the battery from the battery holder.

Warning: Whenever the bottom housing is opened for service, you must do two things:

1. You must clean the original thermal film from the surfaces joining the thermal interface layer and reapply thermal paste to the thermal pipe.

2.You must tighten the four torx screws on the bottom housing to a minimum of

follow either of these steps could cause the computer to overheat and damage internal components.

Refer to the topic, “Thermal Paste Application” for detailed information.

Failure to

Battery

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Logic Board

Tools

This procedure requires the following tools:

• Phillips #2 screwdriver (for the plastic screw)

• Torx-15 screwdriver

Part Location

Note: The battery, RJ-11 board, AirPort card, modem, I/O port covers, and memory (on the top and the bottom of the logic board) need to be removed from the logic board before returning the board to Apple for service.

Preliminary Steps

Before you begin, do the following:

• Position the computer in the service stand.

• Remove the user access plate.

• Remove the bottom housing.

• Remove the RJ-11 board.

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Logic Board

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Procedure

1. Remove the three metal torx screws and the one plastic screw.

Logic Board

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2. Grab the logic board by the battery retainer and the hard drive connector. Lift the board and pull back to release the board from the bottom housing and I/O ports. Note: The I/O port covers may come out with the logic board when it’s removed.

3. Remove the I/O port covers from the logic board.

Warning: Whenever the bottom housing is opened for service, you must do two things:

1.You must clean the original thermal film from the surfaces joining the thermal interface layer and reapply thermal paste to the thermal pipe.

2. You must tighten the four torx screws on the bottom housing to a minimum of

follow either of these steps could cause the computer to overheat and damage internal components.

Refer to the topic, “Thermal Paste Application” for detailed information.

Failure to

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Logic Board

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is separated from the bottom housing could cause these parts to overheat. Short term separation, where the thermal pads are not handled excessively

if you are simply testing the logic board and only detach it for a few minutes)

does not require replacement. Refer to “Thermal Pad Installation” in this chapter for detailed information.

Important: Diagnostic service cables allow the unit to run while the bottom housing is open (as shown above). However, the computer cannot run for more than ﬁve minutes with the bottom housing open. If it is open longer, the CPU may overheat and become damaged.

(an exception would be

Logic Board

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I/O Port Covers

Tools

This procedure requires the following tools:

• No tools are required

Part Location

Preliminary Steps

Before you begin, do the following:

• Position the computer in the service stand.

• Remove the user access plate.

• Remove the bottom housing.

• Remove the RJ-11 board

• Remove the logic board.

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I/O Port Covers

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Procedure

1. Gently remove the I/O port covers from the logic board.

Warning: Whenever the bottom housing is opened for service, you must do two things:

1.You must clean the original thermal film from the surfaces joining the thermal interface layer and reapply thermal paste to the thermal pipe.

2. You must tighten the four torx screws on the bottom housing to a minimum of

follow either of these steps could cause the computer to overheat and damage internal components.

Refer to the topic, “Thermal Paste Application” for detailed information.

Failure to

I/O Port Covers

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Thermal Pad Installation

Tools

• No tools are required.

• Thermal pad kit

Part Location

Warning: Whenever the logic board is removed, you must install new thermal pads to three surfaces (shown above). Failure to apply these pads could cause the computer to overheat and possibly damage the internal components. Note:

you are simply testing the logic board and only detach it for a few minutes

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An exception would be if

Thermal Pad Installation

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Procedure

1. Remove the old thermal pads (shown below) from the bottom housing. Note: If you don’t see all three thermal pads on the bottom housing, check the bottom side of the logic board. The thermal pads may stick to the logic board. Either way, remove the old thermal pads.

2. Using the thermal pad kit, remove the clear protective backing from the new thermal pads.

3. Place the new thermal pads on the bottom housing. Press down on the blue protective backing to make sure the thermal pad has even contact with the bottom housing. There should be no air pockets.

4. Remove the blue protective backing from the new thermal pad. Note: Avoid unnecessary contact with either side of the thermal pad as dirt and body oils reduce the thermal pad's conductivity.

5. Holding the logic board by the battery retainer and the internal drive cable connector, slide the logic board back into the bottom housing (make sure the I/O port covers are on the logic board). Important: Do not push on the heatsink for leverage, as you could knock it off the chip.

Thermal Pad Installation

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AC Line Filter

Tools

This procedure requires the following tools:

• Torx-10 screwdriver

Part Location

Preliminary Steps

Before you begin, do the following:

• Position the computer in the service stand.

• Remove the user access plate.

• Remove the bottom housing.

• Remove the RJ-11 board.

• Remove the logic board.

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AC Line Filter

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Procedure

1. Peel back the black insulator on the bottom housing to access the AC line ﬁlter screws.

2. Remove two screws and lift the AC line ﬁlter from the bottom housing. Note: The AC line port cover plug may fall out of the bottom housing when you remove the AC line ﬁlter. Place the plug back into the bottom housing before reinstalling the AC line ﬁlter.

AC Line Filter

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Warning: Whenever the bottom housing is opened for service, you must do two things:

1.You must clean the original thermal film from the surfaces joining the thermal interface layer and reapply thermal paste to the thermal pipe.

2. You must tighten the four torx screws on the bottom housing to a minimum of

follow either of these steps could cause the computer to overheat and damage internal components.

Refer to the topic, “Thermal Paste Application” for detailed information.

Warning: Whenever the logic board is separated from the bottom housing, you must install new thermal pads to three surfaces on the bottom housing. The thermal pads help cool components on the logic board. Failure to apply these pads whenever the logic board is separated from the bottom housing could cause these parts to overheat. Short term separation, where the thermal pads are not handled excessively

(an exception would be

if you are simply testing the logic board and only detach it for a few minutes)

does not require replacement.

Refer to “Thermal Pad Installation” in this chapter for detailed information.

Failure to

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AC Line Filter

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Drive Carrier Assembly (Optical and Hard Drive)

Tools

This procedure requires the following tools:

• Torx-10 screwdriver

Part Location

Preliminary Steps

Before you begin, do the following:

• Position the computer in the service stand with the door facing up.

• Remove the user access plate.

• Remove the bottom housing.

Drive Carrier Assembly (Optical and Hard Drive)

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Procedure

1. Rotate the base unit so the optical drive door is facing up (as shown below).

2. Remove two screws on the EMI shield. Carefully lift the shield and peel the copper tape off the drive.

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Drive Carrier Assembly (Optical and Hard Drive)

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3. Remove four screws attaching the drive carrier to the metal chassis (also known as the Faraday cage).

Drive Carrier Assembly (Optical and Hard Drive)

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4. With the drive door still positioned at the top, look for the white plastic clip attached to the side of the drive carrier. Open the clip and remove the Airport antenna and the video cable from the cable clip.

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Drive Carrier Assembly (Optical and Hard Drive)

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5. Grasp the carrier on both sides. Lift and pull the carrier in the direction of the arrow. Once the carrier is out, ﬂip the carrier to the right to disconnect the power cables. Note: The carrier ﬁts snugly into the chassis.

6. Disconnect the data cables.

7. Peel the white wrapper up to access the screws connecting the hard drive to the carrier.

Drive Carrier Assembly (Optical and Hard Drive)

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8. Remove the hard drive from the carrier.

9. Remove four screws (shown by circles) to remove the optical drive from the carrier.

10. Slide the optical drive out of the carrier. Be careful of the black plastic dust ﬁlter on the carrier. It is very fragile and can rip easily if not handled properly. Note: The silver insulator is part of the carrier assembly.

Warning: Whenever the bottom housing is opened for service, you must do two things:

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Drive Carrier Assembly (Optical and Hard Drive)

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1.You must clean the original thermal film from the surfaces joining the thermal interface layer and reapply thermal paste to the thermal pipe.

2. You must tighten the four torx screws on the bottom housing to a minimum of 17 in.-lbs. If you do not have a torque driver, you will have to make sure these screws are tightened by hand FIRMLY, BUT NOT FORCIBLY. Or, purchase the service tool (076-0899) in order to ensure the thermal pipe is firmly mated with the top base. If the bottom housing is not securely attached to the base in this fashion, the CPU may overheat and become damaged. Failure to follow either of these steps could cause the computer to overheat and damage internal components.

Refer to the topic, “Thermal Paste Application” for detailed information.

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Power Supply

Tools

This procedure requires the following tools:

• Torx-10 screwdriver

Part Location

Preliminary Steps

Before you begin, do the following:

• Position the computer in the service stand and rotate the door to the right.

• Remove the user access plate.

• Remove the bottom housing.

• Remove the drive carrier assembly.

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Power Supply

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Procedure

1. Remove the two power supply screws circled below.

Power Supply

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2. Open the optical drive door as shown to locate the two hidden screws near the drive door. Remove the four screws. Note: Support the metal plate and power supply as you remove the screws.

Important: The two screws near the door hinge are shorter than the other power supply screws. Failure to replace the shorter screws into their correct location will scratch the top housing. See step 4, Replacement Note.

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Power Supply

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3. Remove the power supply from the chassis, keeping the two halves connected.

Power Supply

4. Replacement Note: When replacing the metal plate (see picture above) that sits on top of the power supply, make certain that the two shorter screws are inserted into the screw holes near the optical door. If the longer screws are inserted by mistake, the screws will scratch the top housing (circled below).

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Warning: Whenever the bottom housing is opened for service, you must do two things:

1.You must clean the original thermal film from the surfaces joining the thermal interface layer and reapply thermal paste to the thermal pipe.

2. You must tighten the four torx screws on the bottom housing to a minimum of 17 in.-lbs. If you do not have a torque driver, you will have to make sure these screws are tightened by hand FIRMLY, BUT NOT FORCIBLY. Or, purchase the service tool (076-0899) in order to ensure the thermal pipe is firmly mated with the top base. If the bottom housing is not securely attached to the base in this fashion, the CPU may overheat and become damaged. Failure to follow either of these steps could cause the computer to overheat and damage internal components.

Refer to the topic, “Thermal Paste Application” for detailed information.

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Power Supply

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Optical Drive Door

Tools

This procedure requires the following tools:

• Torx-10 screwdriver

• Needlenose pliers

Part Location

Optical Drive Door

Preliminary Steps

Before you begin, do the following:

• Position the computer in the service stand.

• Remove the user access plate.

• Remove the bottom housing.

• Remove the drive carrier assembly.

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Procedure

1. Remove the four screws on the power supply metal shield. Set the shield aside. Important: The two screws near the door hinge are shorter than the other power supply screws. Failure to replace the shorter screws to their correct location will scratch the top housing. See step 4, Replacement Note in the Power Supply section for a picture.

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Optical Drive Door

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2. Slide the plastic door frame off the chassis.

3. Carefully remove the two door springs with a needlenose pliers.

Optical Drive Door

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4. Remove the door hinge screws.

5. Open the door open.

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Optical Drive Door

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6. Slide the door and hinge off the frame. Remove the door from the base.

Warning: Whenever the bottom housing is opened for service, you must do two things:

1.You must clean the original thermal film from the surfaces joining the thermal interface layer and reapply thermal paste to the thermal pipe.

2. You must tighten the four torx screws on the bottom housing to a minimum of 17 in.-lbs. If you do not have a torque driver, you will have to make sure these screws are tightened by hand FIRMLY, BUT NOT FORCIBLY. Or, purchase the service tool (076-0899) in order to ensure the thermal pipe is firmly mated with the top base. If the bottom housing is not securely attached to the base in this fashion, the CPU may overheat and become damaged. Failure to follow either of these steps could cause the computer to overheat and damage internal components.

Refer to the topic, “Thermal Paste Application” for detailed information.

Optical Drive Door

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Speaker, Internal

Tools

This procedure requires the following tools:

• Torx-10 screwdriver

Part Location

Preliminary Steps

Before you begin, do the following:

• Position the computer in the service stand.

• Remove the user access plate.

• Remove the bottom housing.

• Remove the drive carrier assembly.

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Speaker, Internal

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Procedure

1. Loosen the two screws enough to slide the speaker off the metal posts. Disconnect the speaker cable.

Warning: Whenever the bottom housing is opened for service, you must do two things:

1.You must clean the original thermal film from the surfaces joining the thermal interface layer and reapply thermal paste to the thermal pipe.

2. You must tighten the four torx screws on the bottom housing to a minimum of 17 in.-lbs. If you do not have a torque driver, you will have to make sure these screws are tightened by hand FIRMLY, BUT NOT FORCIBLY. Or, purchase the service tool (076-0899) in order to ensure the thermal pipe is firmly mated with the top base. If the bottom housing is not securely attached to the base in this fashion, the CPU may overheat and become damaged. Failure to follow either of these steps could cause the computer to overheat and damage internal components.

Refer to the topic, “Thermal Paste Application” for detailed information.

Speaker, Internal

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Fan

Tools

This procedure requires the following tools:

• Torx-15 screwdriver

Part Location

Preliminary Steps

Before you begin, do the following:

• Position the computer in the service stand.

• Remove the user access plate.

• Remove the bottom housing.

• Remove the drive carrier assembly.

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Fan

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Procedure

1. Remove the two fan screws and disconnect the fan connector.

2. Lift the fan out of the chassis (Faraday cage).

Warning: Whenever the bottom housing is opened for service, you must do two things:

1.You must clean the original thermal film from the surfaces joining the thermal interface layer and reapply thermal paste to the thermal pipe.

2. You must tighten the four torx screws on the bottom housing to a minimum of 17 in.-lbs. If you do not have a torque driver, you will have to make sure these screws are tightened by hand FIRMLY, BUT NOT FORCIBLY. Or, purchase the service tool (076-0899) in order to ensure the thermal pipe is firmly mated with the top base. If the bottom housing is not securely attached to the base in this fashion, the CPU may overheat and become damaged. Failure to follow either of these steps could cause the computer to overheat and damage internal components.

Refer to the topic, “Thermal Paste Application” for detailed information.

Fan

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Power Supply Insulators

Tools

No tools are required for this procedure.

Part Location

Preliminary Steps

Before you begin, do the following:

• Position the computer in the service stand.

• Remove the user access plate.

• Remove the bottom housing.

• Remove the drive carrier assembly.

• Remove the power supply.

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Power Supply Insulators

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Procedure

1. Carefully pull the insulators from the chassis (Faraday cage). These are attached to the chassis with double-sided tape.

Warning: Whenever the bottom housing is opened for service, you must do two things:

1.You must clean the original thermal film from the surfaces joining the thermal interface layer and reapply thermal paste to the thermal pipe.

2. You must tighten the four torx screws on the bottom housing to a minimum of 17 in.-lbs. If you do not have a torque driver, you will have to make sure these screws are tightened by hand FIRMLY, BUT NOT FORCIBLY. Or, purchase the service tool (076-0899) in order to ensure the thermal pipe is firmly mated with the top base. If the bottom housing is not securely attached to the base in this fashion, the CPU may overheat and become damaged. Failure to follow either of these steps could cause the computer to overheat and damage internal components.

Refer to the topic, “Thermal Paste Application” for detailed information.

Power Supply Insulators

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Neck Cable Retainer (under fan)

Tools

This procedure requires the following tools:

• Torx-10 screwdriver

Part Location

Note: View the document at a larger size to enlarge this graphic.

Preliminary Steps

Before you begin, do the following:

• Position the computer in the service stand.

• Remove the user access plate.

• Remove the bottom housing.

• Remove the drive carrier assembly.

• Remove the power supply.

• Remove the fan.

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Neck Cable Retainer (under fan)

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Procedure

1. WIth the optical door oriented upward, remove the four screws connecting the plastic cable retainer to the chassis (Faraday cage).

Note: View the document at a larger size to enlarge this graphic.

2. Lift the plastic cable retainer from the chassis. Note: The fan gasket is stuck to the back side of the plastic cable retainer.

Warning: Whenever the bottom housing is opened for service, you must do two things:

1.You must clean the original thermal film from the surfaces joining the thermal interface layer and reapply thermal paste to the thermal pipe.

2. You must tighten the four torx screws on the bottom housing to a minimum of 17 in.-lbs. If you do not have a torque driver, you will have to make sure these screws are tightened by hand FIRMLY, BUT NOT FORCIBLY. Or, purchase the service tool (076-0899) in order to ensure the thermal pipe is firmly mated with the top base. If the bottom housing is not securely attached to the base in this fashion, the CPU may overheat and become damaged. Failure to follow either of these steps could cause the computer to overheat and damage internal components.

Refer to the topic, “Thermal Paste Application” for detailed information.

Neck Cable Retainer (under fan)

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Fan Gasket

Tools

No tools are required for this procedure.

Part Location

Preliminary Steps

Before you begin, do the following:

• Position the computer in the service stand.

• Remove the user access plate.

• Remove the bottom housing.

• Remove the drive carrier assembly.

• Remove the power supply.

• Remove the fan.

• Remove the plastic cable retainer.

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Fan Gasket

Page 64

Procedure

1. Remove the plastic cable retainer and turn it over. Gently peel the fan gasket off the back of the cable retainer.

Warning: Whenever the bottom housing is opened for service, you must do two things:

1.You must clean the original thermal film from the surfaces joining the thermal interface layer and reapply thermal paste to the thermal pipe.

2. You must tighten the four torx screws on the bottom housing to a minimum of 17 in.-lbs. If you do not have a torque driver, you will have to make sure these screws are tightened by hand FIRMLY, BUT NOT FORCIBLY. Or, purchase the service tool (076-0899) in order to ensure the thermal pipe is firmly mated with the top base. If the bottom housing is not securely attached to the base in this fashion, the CPU may overheat and become damaged. Failure to follow either of these steps could cause the computer to overheat and damage internal components.

Refer to the topic, “Thermal Paste Application” for detailed information.

Fan Gasket

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Cap, Neck Spoke Retainer

Tools

This procedure requires the following tools:

• Torx-10 screwdriver

Part Location

Preliminary Steps

Before you begin, do the following:

• Position the computer in the service stand.

• Remove the user access plate.

• Remove the bottom housing.

• Remove the drive carrier assembly.

• Remove the power supply.

• Remove the fan.

• Remove the plastic cable retainer.

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Cap, Neck Spoke Retainer

Page 66

Procedure

1. The neck cables are highlighted below. Note the cable routing, including the blind mate connector orientation before removing the cap screws and neck cap. Note: View the document at a larger size to enlarge the next two graphics.

2. Loosen the three silver screws (circled below) to remove the neck cap. Lift the cap off the spokes. Note: The two black screws keep the neck attached to the base.

Cap, Neck Spoke Retainer

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Warning: Whenever the bottom housing is opened for service, you must do two things:

1.You must clean the original thermal film from the surfaces joining the thermal interface layer and reapply thermal paste to the thermal pipe.

2. You must tighten the four torx screws on the bottom housing to a minimum of 17 in.-lbs. If you do not have a torque driver, you will have to make sure these screws are tightened by hand FIRMLY, BUT NOT FORCIBLY. Or, purchase the service tool (076-0899) in order to ensure the thermal pipe is firmly mated with the top base. If the bottom housing is not securely attached to the base in this fashion, the CPU may overheat and become damaged. Failure to follow either of these steps could cause the computer to overheat and damage internal components.

Refer to the topic, “Thermal Paste Application” for detailed information.

64 iMac (Flat Panel) Take Apart

Cap, Neck Spoke Retainer

Page 68

Blind Mate Connector

Tools

This procedure requires the following tools:

• Torx-10 screwdriver

Part Location

Preliminary Steps

Before you begin, do the following:

• Position the computer in the service stand.

• Remove the user access plate.

• Remove the bottom housing.

• Remove the drive carrier assembly.

• Remove the power supply.

• Remove the fan.

• Remove the plastic cable retainer.

• Remove the cap neck spoke retainer.

Blind Mate Connector

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Procedure

1. Remove the two blind mate screws. Replacement Note: The tab on the blind mate connector faces inward.

2. Lift the blind mate connector off the chassis. Note: The blind mate connector is part of the neck assembly.

Replacement Notes:

Blind Mate Connector: Make sure to replace the blind mate connector into the chassis

with the tab facing inward (toward the fan). And, when tightening the screws, the blind mate connector should have some play; do not tighten down so it doesn’t move at all.

Warning: Whenever the bottom housing is opened for service, you must do two things:

1.You must clean the original thermal film from the surfaces joining the thermal interface layer and reapply thermal paste to the thermal pipe.

2. You must tighten the four torx screws on the bottom housing to a minimum of 17 in.-lbs. If you do not have a torque driver, you will have to make sure these screws are tightened by hand FIRMLY, BUT NOT FORCIBLY. Or, purchase the service tool (076-0899) in order to ensure the thermal pipe is firmly mated with the top base. If the bottom housing is not securely attached to the base in this fashion, the CPU may overheat and become damaged. Failure to follow either of these steps could cause the computer to overheat and damage internal components.

Refer to the topic, “Thermal Paste Application” for detailed information.

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Blind Mate Connector

Page 70

Chassis (Faraday Cage)

Tools

This procedure requires the following tools:

• Torx-10 screwdriver

• Torx-8 screwdriver for the logo screw

Part Location

Preliminary Steps

Before you begin, do the following:

• Position the computer in the service stand.

• Remove the user access plate.

• Remove the bottom housing.

• Remove the drive carrier assembly.

• Remove the power supply.

• Remove the fan.

Chassis (Faraday Cage)

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• Remove the plastic cable retainer (under the fan).

• Remove the neck cap spoke retainer.

• Remove the blind mate connector screws.

Procedure

1. Note: To make sure the computer is oriented correctly before taking the unit apart any further, the speaker should be on the left and the blind mate connector on the right, and the two black screws should be in these locations (shown below).

2. Bundle the neck cables to one side (as shown). Supporting the base, remove the two black screws. These screws connect the neck to the base assembly.

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Chassis (Faraday Cage)

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3. Carefully feed the neck cables through the hole in the Faraday cage. Important: The Faraday cage is very heavy and has sharp edges; handle with care.

Chassis (Faraday Cage)

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4. Pull the outer shell (with Faraday attached) away from the neck. Note: There is no need to remove the outer shell from the Faraday unless you are replacing a scratched or damaged outer shell.If you are removing the shell from the Faraday cage, go on to the next step.

5. Note: Perform this step only if you are replacing the outer shell. Remove the three screws in the base of the Faraday cage to separate the shell from the Faraday cage.

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Chassis (Faraday Cage)

Page 74

Housing, Outer Shell, Plastic

Tools

This procedure requires the following tools:

• Torx-10 screwdriver

Part Location

Preliminary Steps

Before you begin, do the following:

• Position the computer in the service stand.

• Remove the user access plate.

• Remove the bottom housing.

• Remove the drive carrier assembly.

• Remove the power supply.

• Remove the power supply insulators.

• Remove the fan.

• Remove the plastic neck cable retainer (under the fan).

• Remove the cap spoke holder.

Housing, Outer Shell, Plastic

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• Remove the blind mate connector screws.

Procedure

1. Carefully feed the neck cables through the hole in the Faraday cage. Important: The Faraday cage is very heavy and has sharp edges; handle with care.

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Housing, Outer Shell, Plastic

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2. Pull the outer shell (with Faraday attached) away from the neck. Note: There is no need to remove the outer shell from the Faraday unless you are replacing the outer shell. Important: Be careful not to scratch the white paint on the inside of the housing shell and the metal neck plate (with holes).

3. Remove the three screws in the base of the Faraday cage to separate the shell from the Faraday cage.

Housing, Outer Shell, Plastic

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Warning: Whenever the bottom housing is opened for service, you must do two things:

1.You must clean the original thermal film from the surfaces joining the thermal interface layer and reapply thermal paste to the thermal pipe.

2. You must tighten the four torx screws on the bottom housing to a minimum of 17 in.-lbs. If you do not have a torque driver, you will have to make sure these screws are tightened by hand FIRMLY, BUT NOT FORCIBLY. Or, purchase the service tool (076-0899) in order to ensure the thermal pipe is firmly mated with the top base. If the bottom housing is not securely attached to the base in this fashion, the CPU may overheat and become damaged. Failure to follow either of these steps could cause the computer to overheat and damage internal components.

Refer to the topic, “Thermal Paste Application” for detailed information.

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Housing, Outer Shell, Plastic

Page 78

Display, Flat Panel

Tools

This procedure requires the following tools:

• 1.5 mm hex tool

• Plastic stylus to lift the panel

Part Location

Display, Flat Panel

Preliminary Steps

Before you begin, do the following:

• Position the computer in the service stand.

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Procedure

1. Remove ten screws connecting the back cover to the ﬂat panel LCD display.

2. It is not necessary to remove the two screws shown below; these attach to the wireless antenna. Note: The wireless antenna screws are not self-tapping.

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Display, Flat Panel

Page 80

3. With a plastic tool, raise the display to access cables underneath the ﬂat panel.

4. Disconnect the inverter cable shown below.

Display, Flat Panel

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5. Raise the display to disconnect the circled items: the antenna, the inverter cable, the microphone, and the power on LED. Then, peel the tape away from the video connector and carefully pry the video cable clip open to release the video cable (see next page for a close up of the clip). Pry the ferrite bead from the side or from the back. The ferrite bead is fragile and could break if a screwdriver is placed in the middle of the ferrite bead and used as leverage to remove the bead. Note: View this page at a larger size to enlarge the graphic.

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Display, Flat Panel

Page 82

6. This shows a close up of the video cable, ferrite bead, and video cable clip. After removing the tape, carefully use a screwdriver to pry the ferrite bead from the video cable clip. Pry the ferrite bead from the side or from the back. Note: The ferrite bead is fragile and could break if a screwdriver is placed in the middle of the ferrite bead and is used as leverage to remove the bead.

Display, Flat Panel

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7. Lift the ﬂat panel off the back cover. You are left with the LCD ﬂat panel service part.

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Display, Flat Panel

Page 84

Inverter

Tools

This procedure requires the following tools:

• Torx-8 screwdriver

Part Location

Inverter

Preliminary Steps

Before you begin, do the following:

• Position the computer in the service stand.

• Remove the flat panel display.

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Procedure

1. Remove the three screws and then slide the inverter in the direction of the arrow.

2. Turn the inverter over and disconnect the inverter neck cable.

3. Remove the inverter from the display support shield.

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Inverter

Page 86

Antenna, Wireless

Tools

This procedure requires the following tools:

• Torx-6 screwdriver, or allen head

• Torx-8 screwdriver

• 5mm socket

Part Location

Antenna, Wireless

Preliminary Steps

Before you begin, do the following:

• Position the computer in the service stand.

• Remove the flat panel display.

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Procedure

1. Remove two external T-6 screws attaching the antenna to the back cover Note: View this page at a larger size to enlarge the graphics.

2. Remove the two internal antenna screws on the sides (shown by the circles) and the two 5mm nuts connecting the wireless antenna to the panel shield.

3. Remove the antenna from the metal clips on the panel shield. Lift the antenna from the panel shield.

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Antenna, Wireless

Page 88

Panel Shield

Tools

This procedure requires the following tools:

• Torx-8 screwdriver

• Torx-10 screwdriver

Part Location

Panel Shield

Preliminary Steps

Before you begin, do the following:

• Position the computer in the service stand.

• Remove the flat panel display.

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Procedure

1. Remove the three T-8 screws on the metal cable retainer. Lift the cable retainer off the panel shield.

2. Remove the four T-10 screws on the panel shield. Next, release the cables from the metal clips on the panel shield. Note: View this page at a larger size to enlarge this graphic.

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Panel Shield

Page 90

3. Gently pull the cables through the hole in the panel shield.

Panel Shield

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4. Line up the notches on the panel shield hole with the video cable. Gently pull the video cable through the panel shield (See next graphic for a close-up of the video cable going through the hole). Lift the shield off the back cover being careful not to scratch the white coating on the back cover.

Note: View this page at a larger size to enlarge the graphics.

5. This is a close-up of the video cable going through the hole in the panel shield.

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Panel Shield

Page 92

Back Cover, Display

Tools

No tools are required.

Part Location

Preliminary Steps

Before you begin, do the following:

• Position the computer in the service stand.

• Remove the flat panel display.

• Remove the panel shield.

Back Cover, Display

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Procedure

1. Lift the display cover off the neck assembly.

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Back Cover, Display

Page 94

Neck Assembly

Tools

This procedure requires the following tools:

• Torx-10 screwdriver

Part Location

Neck Assembly

Preliminary Steps

Before you begin, do the following:

• Position the computer in the service stand.

• Remove the user access plate.

• Remove the bottom housing.

• Remove the drive carrier assembly.

• Remove the power supply.

• Remove the power supply insulators.

• Remove the fan.

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• Remove the plastic cable retainer (under the fan).

• Remove the cap spoke holder.

• Remove the blind mate connector screws.

• Remove the Faraday cage.

• Remove the flat panel display.

• Remove the panel shield.

• Remove the back cover

Procedure

The neck assembly is attached to the computer base at one end and to the ﬂat panel at the other end. To remove the neck assembly from the computer, follow all the take-apart procedures listed above. When you are ﬁnished, you will be left with the neck assembly shown below.

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Neck Assembly

Page 96

Base Reassembly

Procedure

1. Refer to the Exploded View drawing during reassembly.

2. Attach the metal neck plate (the round, metal plate with holes) and the round white plastic retainer to the top of the Faraday cage. These two parts are visible in the picture below.

3. With the optical door facing upward, install the Chassis (Faraday cage) into the base’s top housing. Replace the three screws that attach the plastic top housing to the chassis.

Base Reassembly

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