Apple iMac (USB 2.0) 03 Service Manual

Service Source

iMac (USB 2.0)

© 2003 Apple Computer, Inc. All rights reserved.
iMac (USB 2.0)
- 1
Service Source

Basics

iMac (USB 2.0)
© 2003 Apple Computer, Inc. All rights reserved.

Overview

The iMac (USB 2.0) computers are powered by the PowerPC G4 processors. Two models are available: the 17-inch widescreen LCD (1.25 GHZ) or the 15-inch LCD flat screen (1 GHz). The computer also includes 80GB hard drives, 256MB DDR333 SDRAM, two FireWire 400 ports and three USB 2.0 ports. The 17-inch widescreen and the 15-inch flat panel computers come with Mac OS X version 10.2.7 installed as the default system .
Overview

How to identify these models

Verify the processor speed. If the system is up and running, select “About this Mac” under the Apple icon in the Finder. Or, select the “More Info” button on the “About this Mac” window. Apple System Profiler opens and displays the machine speed under “Hardware Overview.” The 15-inch iMac has a 1GHz PowerPC G4 processor and the 17-inch iMac has a 1.25GHz PowerPC G4 processor.
iMac (USB 2.0) Basics - 1

What’s New

New Features

Processor and speed —The microprocessor in the iMac (Flat Panel, USB 2.0) is a
PowerPC G4 with a clock speed of 1 GHz in the 15" configuration and a 1.25 GHz in the 17" configuration.
USB 2.0 ports — The computer has three USB 2.0 ports.
Memory — This computer comes with 256 MB of DDR333 SDRAM installed in an internal
standard 186-pin DIMM expansion slot, with a build-to-order options of 512 MB . A second user-accessible slot accepts an SO-DIMM with up to 512 MB. The maximum total memory is 1 GB.
System bus — The speed of the system bus is 167 MHz.
Graphics acceleration — The A GP 4X g raphics IC used is either an NVidia GeF orce4MX
or and NVidia GeForce FX5200 Ultra.
Video RAM The video hardware includes either 32 MB or 64 MB of DDR SDRAM,
which supports 3D features and millions of colors in all resolutions.
External video monitor — The e xternal display connector supports mini-VGA, composite,
S-video monitors and projectors, and television sets. A video adapter with composite and S-video connectors and a VGA-out adapter are available separately.
Bluetooth support (optional) — Bluetooth support is available as a build-to-order option
to enable short-range wireless connections between desktop and laptop computers and a host of other peripheral devices.
2 - iMac (USB 2.0) Basics
What’s New
Standard Configurations
Features 15-inch 17-inch
CPU and speed
System bus speed Main memory
Display
Graphics IC
Graphics memory Hard disk drive
Optical drive External monitor
adapter
Communication fea­tures
1GHz PowerPC G4 1.25GHz PowerPC G4
167 MHz 167 MHz 256 MB SDRAM,
expandable up to 1 GB 15-inch flat panel 17-inch, wide-screen flat
NVIDIA GeForceMX NVIDIA GeForce FX
32 MB DDR RAM 64 MB DDR RAM 80 GB Ultra A TA-66 7200
rpm
Tray-load Combo drive Tray-load SuperDrive Mini-VGA or S-video/
composite
10/100 Ethernet; 56K V.92 fax modem
256 MB SDRAM, expandable up to 1 GB
panel
5200 Ultra
80 GB Ultra A TA-66 7200 rpm
Mini-VGA or S-video/ composite
10/100 Ethernet; 56K V.92 fax modem
What’s New
Wireless features
Optional 54 Mbps AirPort Extreme Card; optional internal Bluetooth
Optional 54 Mbps AirPort Extreme Card; optional internal Bluetooth
iMac (USB 2.0) Basics - 3

Serial Number Location

To identify a particular model of iMac (USB 2.0), check the computer’s serial number, which lists the model’s configuration. The serial number is located on the bottom of the computer, on the metal access plate, or on the inside of the optical drive door (bottom photo).
4 - iMac (USB 2.0) Basics
Serial Number Location
Serial Number Location
iMac (USB 2.0) Basics - 5
Service Source

Take Apart

iMac (USB 2.0)
© 2003 Apple Computer, Inc. All rights reserved.

General Information

Overview

The Take Apart chapter includes take apart procedures for both the 15" and 17" iMac (USB 2.0) computers. If you are f amiliar with taking apart iMac (Flat Panel) computers, y ou will find that the procedures for these newer models haven’t changed. The changes consist of faster processors, f aster system bus , larger capacity hard drives, and three USB
2.0 ports.

New Procedures

The following Take Apart sections were updated:
• Display, Inverter, Back Cover, and the Neck Assembly

Tools

The following tools are recommended for the take apart procedures.
• The service stand (076-0898)
• Thermal paste (922-4757)
Torque driver, 17" LB (076-0899)
• 1.5 mm hex driver (for LCD bezel screws)
• #0 Phillips screwdriver)
• Torx screwdriver set (6, 8, 10, 15)
• Plastic flatblade screwdriver or stylus (922-5065)
• Needlenose pliers
• ESD wriststrap and mat
General Information
iMac (USB 2.0) Take Apart - 1

Service Stand

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.
2 - iMac (USB 2.0) Take Apart
General Information

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.
iMac (USB 2.0) Take Apart - 3

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.
4 - iMac (USB 2.0) Take Apart
User Access Plate

AirPort Extreme Card

Tools

This procedure requires no tools.

Part Location

Preliminary Steps

Before you begin, do the following:
• Position the computer in the service stand.
• Remove the user access plate.
AirPort Extreme Card
iMac (USB 2.0) Take Apart - 5

Procedure

1. Unplug all cables from the computer except the power cord.
Important: To avoid electrostatic discharge, always ground yourself by touching
2. 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. Pull the plastic tab on the AirPort Extreme card to remove it from the slot. Disconnect the AirPort antenna from the card.
6 - iMac (USB 2.0) Take Apart
AirPort Extreme Card
Memory, SO-DIMM (user­installable)

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.
Note: DIMMs used in this slot should be a low-profile PC2700 (DDR333) SO-DIMM. Only
the SO-DIMM slot is accessible by the user.

Memory, SO-DIMM (user-installable)

iMac (USB 2.0) Take Apart - 7

Procedure

1. Unplug all cables from the computer except the power cord.
Important: To avoid electrostatic discharge, always ground yourself by touching
2. 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. Release the memory by spreading apart the tabs in the expansion slot from the notches in the card.
8 - iMac (USB 2.0) Take Apart
Memory, SO-DIMM (user-installable)
6. Allow the memory to pop up slightly, and pull it out of the memory slot.
Memory, SO-DIMM (user-installable)
iMac (USB 2.0) Take Apart - 9

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.
10 - iMac (USB 2.0) Take Apart
Bottom Housing

Procedure

1. When opening the bottom housing, rotate the base so the optical drive door is on the right. (This position is less stressful on the internal cables when the bottom is open).
2. Remove the four torx screws.
Replacement Note:
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. For more information, refer to “Thermal Paste 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 you do
iMac (USB 2.0) Take Apart - 11
3. Gently open the bottom housing in the direction of the arrow. Disconnect the cables.
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4. Disconnect the following:
C
D
E
A
Grounding screw
B
Bluetooth connector (if Bluetooth board is present, this will be connected)
AirPort connector
AC line filter connector
TMDS video connector
F Inverter, speaker, fan connector G Optical cable and connector H Hard drive cable and connector I Power Supply connector
5. 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 all thermal interface mating surfaces, and reapply thermal paste to the mating surfaces on the thermal pipe.
2. You must tighten the four torx screws on the bottom housing to a minimum of 17 in.-lbs. Use a torque driver (service tool 076-0899) to ensure that the thermal pipe is firmly mated with the top base. If you do not have a torque driver, you must make sure the screws are tightened by hand FIRMLY, BUT NOT FORCIBLY.
Failure to follow these steps could cause the computer to overheat and damage internal components.
Refer to the topic “Thermal Paste Application” for detailed information.
iMac (USB 2.0) Take Apart - 13

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

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 ball of thermal paste onto the mating surfaces of the thermal pipe.
Thermal Paste Application
iMac (USB 2.0) Take Apart - 15
3. Replace the bottom housing. Warning: The bottom housing has four torx screws that must be tightened to at least
17 in.-lbs. Use a torque driver (service tool 076-0899) to ensure that the thermal pipe is firmly mated with the top base. If you do not have a torque driver, you must make sure the screws are tightened by hand FIRMLY, BUT NOT FORCIBLY.
Failure to apply the thermal paste as described in this procedure, and failure to tighten the torx screws as directed, could cause the computer to overheat and damage internal components.
Refer to the topic “Thermal Paste Application” for detailed information.
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Thermal Paste Application

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.
RJ-11 Modem Filter Board
iMac (USB 2.0) Take Apart - 17

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 all thermal interface mating surfaces, and reapply thermal paste to the mating surfaces on the thermal pipe.
2. You must tighten the four torx screws on the bottom housing to a minimum of 17 in.-lbs. Use a torque driver (service tool 076-0899) to ensure that the thermal pipe is firmly mated with the top base. If you do not have a torque driver, you must make sure the screws are tightened by hand FIRMLY, BUT NOT FORCIBLY.
Failure to follow these steps could cause the computer to overheat and damage internal components.
Refer to the topic “Thermal Paste Application” for detailed information.
18 - iMac (USB 2.0) Take Apart
RJ-11 Modem Filter Board

Modem

Tools

This procedure requires the following tools:
• Torx-8 screwdriver

Part Location

Modem

Preliminary Steps

Before you begin, do the following:
• Position the computer in the service stand.
• Remove the user access plate.
• Remove the bottom housing.
iMac (USB 2.0) Take Apart - 19

Procedure

1. Remove two screws and disconnect the cable.
2. Lift the modem board 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 all thermal interface mating surfaces, and reapply thermal paste to the mating surfaces on the thermal pipe.
2. You must tighten the four torx screws on the bottom housing to a minimum of 17 in.-lbs. Use a torque driver (service tool 076-0899) to ensure that the thermal pipe is firmly mated with the top base. If you do not have a torque driver, you must make sure the screws are tightened by hand FIRMLY, BUT NOT FORCIBLY.
Failure to follow these steps could cause the computer to overheat and damage internal components.
Refer to the topic “Thermal Paste Application” for detailed information.
20 - iMac (USB 2.0) Take Apart
Modem

Memory (factory-installed)

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.
Memory (factory-installed)
iMac (USB 2.0) Take Apart - 21

Procedure

1. Push down on the ejector tabs to release the memory module.
2. Pull the memory up and out of the slot. Important: Make sure that the memory installed on the logic board is compatible with the system. The computer accepts double-data rate (DDR) SDRAM DIMMs. DIMMs used in this slot must fit the following specification: PC2700 SDRAM DDR333 DIMMs for 167 MHz systems.
Warning: Whenever the bottom housing is opened for service, you must do two things:
1.You must clean the original thermal film from all thermal interface mating surfaces, and reapply thermal paste to the mating surfaces on the thermal pipe.
2. You must tighten the four torx screws on the bottom housing to a minimum of 17 in.-lbs. Use a torque driver (service tool 076-0899) to ensure that the thermal pipe is firmly mated with the top base. If you do not have a torque driver, you must make sure the screws are tightened by hand FIRMLY, BUT NOT FORCIBLY.
Failure to follow these steps could cause the computer to overheat and damage internal components.
Refer to the topic “Thermal Paste Application” for detailed information.
22 - iMac (USB 2.0) Take Apart
Memory (factory-installed)

Battery

Tools

This procedure requires the following tools:
• No tools are required

Part Location

Battery

Preliminary Steps

Before you begin, do the following:
• Position the computer in the service stand.
• Remove the user access plate.
• Remove the bottom housing.
iMac (USB 2.0) Take Apart - 23

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 all thermal interface mating surfaces, and reapply thermal paste to the mating surfaces on the thermal pipe.
2. You must tighten the four torx screws on the bottom housing to a minimum of 17 in.-lbs. Use a torque driver (service tool 076-0899) to ensure that the thermal pipe is firmly mated with the top base. If you do not have a torque driver, you must make sure the screws are tightened by hand FIRMLY, BUT NOT FORCIBLY.
Failure to follow these steps could cause the computer to overheat and damage internal components.
Refer to the topic “Thermal Paste Application” for detailed information.
24 - iMac (USB 2.0) Take Apart
Battery

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 Extreme card, modem, I/O port covers, memory (on the top and the bottom of the logic board), Bluetooth board and the Bluetooth extension cable need to be removed from the logic board before returning the board to Apple for service.
Logic Board

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.
iMac (USB 2.0) Take Apart - 25

Procedure

1. Remove the three torx screws (metal) and one plastic screw.
26 - iMac (USB 2.0) Take Apart
Logic Board
2. Grab the logic board by the battery retainer and the hard drive connector. Lift the board slightly 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 logic board is separated from the bottom housing, you must install new thermal pads to three surfaces on the bottom housing. Failure to apply these pads whenever the logic board is separated from the bottom housing could cause these parts to overheat and could damage internal components. Note: AFTER installing new thermal pads, if you must briefly re-separate the logic board from the housing, it is OK to retain the same, new pads as long as they are not handled excessively. Refer to “Thermal Pad Installation” in this chapter for detailed information.
Warning: Whenever the bottom housing is opened for service, you must do two things:
1.You must clean the original thermal film from all thermal interface mating surfaces, and reapply thermal paste to the mating surfaces on the thermal pipe.
2. You must tighten the four torx screws on the bottom housing to a minimum of 17 in.-lbs. Use a torque driver (service tool 076-0899) to ensure that the thermal pipe is firmly mated with the top base. If you do not have a torque driver, you must make sure the screws are tightened by hand FIRMLY, BUT NOT FORCIBLY.
Failure to follow these steps could cause the computer to overheat and damage internal components.
Refer to the topic “Thermal Paste Application” for detailed information.
Logic Board
iMac (USB 2.0) Take Apart - 27
Bluetooth Board and Cable

Tools

This procedure requires the following tools:
• Phillips #2 jeweler’s 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.
28 - iMac (USB 2.0) Take Apart

Bluetooth Board and Cable

Procedure

1. Ground yourself. Remove the AirPort Extreme card and SO-DIMM memory (if present).
2. Remove the logic board protective cover to access the Bluetooth board
Bluetooth Board and Cable
iMac (USB 2.0) Take Apart - 29
3. Remove the two screws (circled below) on the Bluetooth board.
4. Peel the Kapton tape off the Bluetooth extension cable. Disconnect the extension cable from the Bluetooth board. Note: The Bluetooth wireless extension cable is a separate service part from the Bluetooth board.
5. Lift the Bluetooth board from the connector on the logic board.
Warning: Whenever the logic board is separated from the bottom housing, you must install new thermal pads to three surfaces on the bottom housing. Failure to apply these pads whenever the logic board is separated from the bottom housing could cause these parts to overheat and could damage internal components. Note: AFTER installing new thermal pads, if you must briefly re-separate the logic board from the housing, it is OK to retain the same, new pads as long as they are not handled excessively. Refer to “Thermal Pad Installation” in this chapter for detailed information.
Warning: Whenever the bottom housing is opened for service, you must do two things:
1.You must clean the original thermal film from all thermal interface mating surfaces, and reapply thermal paste to the mating surfaces on the thermal pipe.
2. You must tighten the four torx screws on the bottom housing to a minimum of 17 in.-lbs. Use a torque driver (service tool 076-0899) to ensure that the thermal pipe is firmly mated with the top base. If you do not have a torque driver, you must make sure the screws are tightened by hand FIRMLY, BUT NOT FORCIBLY.
Failure to follow these steps could cause the computer to overheat and damage internal components.
Refer to the topic “Thermal Paste Application” for detailed information.
30 - iMac (USB 2.0) Take Apart
Bluetooth Board and Cable

I/O Port Covers

Tools

This procedure requires the following tools:
• No tools are required

Part Location

I/O Port Covers

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.
iMac (USB 2.0) Take Apart - 31

Procedure

1. Gently pull the I/O port covers off 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 all thermal interface mating surfaces, and reapply thermal paste to the mating surfaces on the thermal pipe.
2. You must tighten the four torx screws on the bottom housing to a minimum of 17 in.-lbs. Use a torque driver (service tool 076-0899) to ensure that the thermal pipe is firmly mated with the top base. If you do not have a torque driver, you must make sure the screws are tightened by hand FIRMLY, BUT NOT FORCIBLY.
Failure to follow 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. Failure to apply these pads whenever the logic board is separated from the bottom housing could cause these parts to overheat and could damage internal components. Note: AFTER installing new thermal pads, if you must briefly re-separate the logic board from the housing, it is OK to retain the same, new pads as long as they are not handled excessively. Refer to “Thermal Pad Installation” in this chapter for detailed information.
32 - iMac (USB 2.0) Take Apart
I/O Port Covers

AirPort Antenna Extension Cable

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.
AirPort Antenna Extension Cable
iMac (USB 2.0) Take Apart - 33

Procedure

1. Release the extension cable from the plastic cable clips to remove the cable from the bottom housing. Replacement Note: Be careful not to pinch the antenna extension cable when replacing it.
Warning: Whenever the bottom housing is opened for service, you must do two things:
1.You must clean the original thermal film from all thermal interface mating surfaces, and reapply thermal paste to the mating surfaces on the thermal pipe.
2. You must tighten the four torx screws on the bottom housing to a minimum of 17 in.-lbs. Use a torque driver (service tool 076-0899) to ensure that the thermal pipe is firmly mated with the top base. If you do not have a torque driver, you must make sure the screws are tightened by hand FIRMLY, BUT NOT FORCIBLY.
Failure to follow 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. Failure to apply these pads whenever the logic board is separated from the bottom housing could cause these parts to overheat and could damage internal components. Note: AFTER installing new thermal pads, if you must briefly re-separate the logic board from the housing, it is OK to retain the same, new pads as long as they are not handled excessively. Refer to “Thermal Pad Installation” in this chapter for detailed information.
34 - iMac (USB 2.0) Take Apart
AirPort Antenna Extension Cable

Thermal Pad Installation

Tools

• No tools are required.
• Thermal pad kit (076-0925)

Part Location

Warning: Whenever the logic board is separated from the bottom housing, you must install new thermal pads to two surfaces on the bottom housing. Failure to apply these pads whenever the logic board is separated from the bottom housing could cause these parts to overheat and could damage internal components. Note: AFTER installing new thermal pads, if you must briefly re-separate the logic board from the housing, it is OK to retain the same, new pads as long as they are not handled excessively.
Thermal Pad Installation
iMac (USB 2.0) Take Apart - 35

Procedure

1. Remove the old thermal pads from the bottom housing. Note: If you don’t see the two thermal pads on the bottom housing, check the under side of the logic board. The thermal pads may stick to the logic board. Always remove the old thermal pads, and install new pads if you are taking the unit apart to this level.
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 do wn on the blue protectiv e 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. Slide the logic board back into the bottom housing (make sure the I/O port covers are on the logic board).
36 - iMac (USB 2.0) Take Apart
Thermal Pad Installation

AC Line Filter

Tools

This procedure requires the following tools:
• Torx-10 screwdriver

Part Location

AC Line Filter

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.
iMac (USB 2.0) Take Apart - 37

Procedure

1. Peel the black insulator on the bottom housing back to access the AC line filter screws.
2. Remove two screws and lift the AC line filter from the bottom housing. Note: The port plug may fall out of the AC filter port when you remove the AC line filter. Replace the plug into the opening on the bottom housing before reinstalling the AC line filter.
38 - iMac (USB 2.0) Take Apart
AC Line Filter
Warning: Whenever the bottom housing is opened for service, you must do two things:
1.You must clean the original thermal film from all thermal interface mating surfaces, and reapply thermal paste to the mating surfaces on the thermal pipe.
2. You must tighten the four torx screws on the bottom housing to a minimum of 17 in.-lbs. Use a torque driver (service tool 076-0899) to ensure that the thermal pipe is firmly mated with the top base. If you do not have a torque driver, you must make sure the screws are tightened by hand FIRMLY, BUT NOT FORCIBLY.
Failure to follow 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. Failure to apply these pads whenever the logic board is separated from the bottom housing could cause these parts to overheat and could damage internal components. Note: AFTER installing new thermal pads, if you must briefly re-separate the logic board from the housing, it is OK to retain the same, new pads as long as they are not handled excessively. Refer to “Thermal Pad Installation” in this chapter for detailed information.
AC Line Filter
iMac (USB 2.0) Take Apart - 39

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.
40 - iMac (USB 2.0) Take Apart
Drive Carrier Assembly (Optical and Hard Drive)

Procedure

1. Rotate the base unit so the optical drive door is facing to the right.
2. Remove six screws; two on the EMI shield (with copper tape) and four attaching the drive to the Faraday cage (chassis). Carefully lift the shield and copper tape off the drive. Replacement Note: When replacing the drive EMI shield, be sure to use the two shorter screws.
Drive Carrier Assembly (Optical and Hard Drive)
iMac (USB 2.0) Take Apart - 41
3. Remove the Airport and Bluetooth antennas from the plastic clip on the side of the drive carrier.
42 - iMac (USB 2.0) Take Apart
Drive Carrier Assembly (Optical and Hard Drive)
4. Grasp the carrier by the top and bottom edges. Wiggle the drive carrier out of the chassis pulling the carrier in the direction of the arrow. Note: The carrier fits snugly into the chassis.
5. Disconnect the two power cables; one attaches to the optical drive and the other attaches to the hard drive.
Drive Carrier Assembly (Optical and Hard Drive)
iMac (USB 2.0) Take Apart - 43
6. To remove the hard drive from the carrier, peel the white wrapper up to access the screws (two on each side). Remove the screws, disconnect the data cable, and remove the hard drive out of the carrier.
7. To remove the optical drive, remove four screws (shown by dashed lines), disconnect the optical drive data cable (see lower arrow), and slide the optical drive out of the carrier.
44 - iMac (USB 2.0) Take Apart
Drive Carrier Assembly (Optical and Hard Drive)
Warning: Whenever the bottom housing is opened for service, you must do two things:
1.You must clean the original thermal film from all thermal interface mating surfaces, and reapply thermal paste to the mating surfaces on the thermal pipe.
2. You must tighten the four torx screws on the bottom housing to a minimum of 17 in.-lbs. Use a torque driver (service tool 076-0899) to ensure that the thermal pipe is firmly mated with the top base. If you do not have a torque driver, you must make sure the screws are tightened by hand FIRMLY, BUT NOT FORCIBLY.
Failure to follow these steps could cause the computer to overheat and damage internal components.
Refer to the topic “Thermal Paste Application” for detailed information.
iMac (USB 2.0) Take Apart - 45

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

Procedure

1. Remove the two power supply screws circled below.
Power Supply
iMac (USB 2.0) Take Apart - 47
2. Open the optical drive door as shown. Support the metal plate and power supply as you remove the four 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
3. Lift the power supply and metal shield out of the chassis (Faraday cage).
4. Replacement Note: When replacing the metal shield (see picture above) that sits on top of the power supply, install the two shorter screws near the optical door. If the longer screws are installed by mistake, the screws will scratch the inside of the housing (circled below).
Power Supply
iMac (USB 2.0) Take Apart - 49
Warning: Whenever the bottom housing is opened for service, you must do two things:
1.You must clean the original thermal film from all thermal interface mating surfaces, and reapply thermal paste to the mating surfaces on the thermal pipe.
2. You must tighten the four torx screws on the bottom housing to a minimum of 17 in.-lbs. Use a torque driver (service tool 076-0899) to ensure that the thermal pipe is firmly mated with the top base. If you do not have a torque driver, you must make sure the screws are tightened by hand FIRMLY, BUT NOT FORCIBLY.
Failure to follow 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

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.
iMac (USB 2.0) Take Apart - 51

Procedure

1. Remove four screws on the power supply 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 the Power Supply topic, step 4, Replacement Note, for a picture of what happens when the wrong screws are inserted in the wrong location.
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Optical Drive Door
2. Slide the optical door guide off the chassis and the door hinge tabs (circled).
3. Carefully remove the two door springs with a needlenose pliers.
Optical Drive Door
iMac (USB 2.0) Take Apart - 53
4. Remove the door hinge screws.
5. Open the door.
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Optical Drive Door
6. Slide the door and hinge off the chassis.
Warning: Whenever the bottom housing is opened for service, you must do two things:
1.You must clean the original thermal film from all thermal interface mating surfaces, and reapply thermal paste to the mating surfaces on the thermal pipe.
2. You must tighten the four torx screws on the bottom housing to a minimum of 17 in.-lbs. Use a torque driver (service tool 076-0899) to ensure that the thermal pipe is firmly mated with the top base. If you do not have a torque driver, you must make sure the screws are tightened by hand FIRMLY, BUT NOT FORCIBLY.
Failure to follow 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
iMac (USB 2.0) Take Apart - 55

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

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 all thermal interface mating surfaces, and reapply thermal paste to the mating surfaces on the thermal pipe.
2. You must tighten the four torx screws on the bottom housing to a minimum of 17 in.-lbs. Use a torque driver (service tool 076-0899) to ensure that the thermal pipe is firmly mated with the top base. If you do not have a torque driver, you must make sure the screws are tightened by hand FIRMLY, BUT NOT FORCIBLY.
Failure to follow these steps could cause the computer to overheat and damage internal components.
Refer to the topic “Thermal Paste Application” for detailed information.
Speaker, Internal
iMac (USB 2.0) Take Apart - 57
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

Procedure

1. Remove the two fan screws and disconnect the fan connector.
2. Pull the fan out of the chassis (F arada y cage). Note: The replacement f an includes the mounting bracket.
Warning: Whenever the bottom housing is opened for service, you must do two things:
1.You must clean the original thermal film from all thermal interface mating surfaces, and reapply thermal paste to the mating surfaces on the thermal pipe.
2. You must tighten the four torx screws on the bottom housing to a minimum of 17 in.-lbs. Use a torque driver (service tool 076-0899) to ensure that the thermal pipe is firmly mated with the top base. If you do not have a torque driver, you must make sure the screws are tightened by hand FIRMLY, BUT NOT FORCIBLY.
Failure to follow these steps could cause the computer to overheat and damage internal components.
Refer to the topic “Thermal Paste Application” for detailed information.
Fan
iMac (USB 2.0) Take Apart - 59

Power Supply Insulators

Tools

No tools are required for this procedure.

Part Location

Note: Insulator color and transparency may vary from those shown above.

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

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 all thermal interface mating surfaces, and reapply thermal paste to the mating surfaces on the thermal pipe.
2. You must tighten the four torx screws on the bottom housing to a minimum of 17 in.-lbs. Use a torque driver (service tool 076-0899) to ensure that the thermal pipe is firmly mated with the top base. If you do not have a torque driver, you must make sure the screws are tightened by hand FIRMLY, BUT NOT FORCIBLY.
Failure to follow 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
iMac (USB 2.0) Take Apart - 61

Fan Retainer Bracket (under fan)

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.
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Fan Retainer Bracket (under fan)

Procedure

1. Remove the four screws connecting the fan bracket to the chassis (Faraday cage).
2. Lift the fan bracket out of the chassis. Note the orientation of the neck cables (see below) in the fan bracket before removing the cables. For orientation purposes, the drive door would be on the right.
Fan Retainer Bracket (under fan)
iMac (USB 2.0) Take Apart - 63
Warning: Whenever the bottom housing is opened for service, you must do two things:
1.You must clean the original thermal film from all thermal interface mating surfaces, and reapply thermal paste to the mating surfaces on the thermal pipe.
2. You must tighten the four torx screws on the bottom housing to a minimum of 17 in.-lbs. Use a torque driver (service tool 076-0899) to ensure that the thermal pipe is firmly mated with the top base. If you do not have a torque driver, you must make sure the screws are tightened by hand FIRMLY, BUT NOT FORCIBLY.
Failure to follow 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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Fan Retainer Bracket (under fan)

Fan Gasket

Tools

No tools are required for this procedure.

Part Location

Fan Gasket

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 fan retainer bracket.
iMac (USB 2.0) Take Apart - 65

Procedure

1. Remove the fan retainer bracket and turn it over. Gently peel the fan gasket off the back of the fan bracket.
Warning: Whenever the bottom housing is opened for service, you must do two things:
1.You must clean the original thermal film from all thermal interface mating surfaces, and reapply thermal paste to the mating surfaces on the thermal pipe.
2. You must tighten the four torx screws on the bottom housing to a minimum of 17 in.-lbs. Use a torque driver (service tool 076-0899) to ensure that the thermal pipe is firmly mated with the top base. If you do not have a torque driver, you must make sure the screws are tightened by hand FIRMLY, BUT NOT FORCIBLY.
Failure to follow 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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Fan Gasket

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.
Cap, Neck Spoke Retainer
iMac (USB 2.0) Take Apart - 67

Procedure

1. Before removing the neck cap screws, note the cable routing, including the location of the empty spoke.
2. Note: There are five screws on the neck cap. For this step, remove only the three silver screws and the neck cap. (The two black screws secure the neck to the base.)
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Cap, Neck Spoke Retainer
Warning: Whenever the bottom housing is opened for service, you must do two things:
1.You must clean the original thermal film from all thermal interface mating surfaces, and reapply thermal paste to the mating surfaces on the thermal pipe.
2. You must tighten the four torx screws on the bottom housing to a minimum of 17 in.-lbs. Use a torque driver (service tool 076-0899) to ensure that the thermal pipe is firmly mated with the top base. If you do not have a torque driver, you must make sure the screws are tightened by hand FIRMLY, BUT NOT FORCIBLY.
Failure to follow these steps could cause the computer to overheat and damage internal components.
Refer to the topic “Thermal Paste Application” for detailed information.
Cap, Neck Spoke Retainer
iMac (USB 2.0) Take Apart - 69

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.
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Chassis (Faraday Cage)
• Remove the power supply.
• Remove the fan.
• Remove the plastic cable retainer (under the fan).
• Remove the neck spoke retainer cap.

Procedure

1. Pull the neck cables/white spokes out of their slots and into a b undle . Bundle the neck cables to one side. Supporting the base, remove the two black screws that connect the neck to the Faraday base.
Chassis (Faraday Cage)
iMac (USB 2.0) Take Apart - 71
2. 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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Chassis (Faraday Cage)
3. Pull the outer shell (with Faraday attached) away from the neck.Note: There is no need to remove the outer shell from the F ar ada y unless y ou are replacing the antenna or the outer shell. If you are removing the shell from the Faraday cage, go on to the next step.
4. Note: Perform this step only if you are replacing the antenna or the outer shell. Remove one screw in the base of the Faraday cage to separate the shell from the Faraday cage.
Chassis (Faraday Cage)
iMac (USB 2.0) Take Apart - 73
Replacement Notes: Faraday cage: Look at the exploded view diagram during reassembly. First, attach the
Faraday top cover to the top (OUTSIDE) of the Faraday cage as shown below; the Faraday top cover is keyed. Next, thread the neck cables through the hole in the Faraday cage and install the Faraday cage into the top plastic housing. Replace the screw that holds the plastic housing to the chassis. Attach the black neck cap screws to connect the neck to the chassis. Route the neck cables correctly in the base and replace the fan bracket retainer and three remaining neck cap screws.
Warning: Whenever the bottom housing is opened for service, you must do two things:
1.You must clean the original thermal film from all thermal interface mating surfaces, and reapply thermal paste to the mating surfaces on the thermal pipe.
2. You must tighten the four torx screws on the bottom housing to a minimum of 17 in.-lbs. Use a torque driver (service tool 076-0899) to ensure that the thermal pipe is firmly mated with the top base. If you do not have a torque driver, you must make sure the screws are tightened by hand FIRMLY, BUT NOT FORCIBLY.
Failure to follow 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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Chassis (Faraday Cage)

Antenna, Wireless

Tools

This procedure requires the following tools:
• Torx-8 screwdriver

Part Location

Antenna, Wireless

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 optical drive door.
• Remove the internal speaker.
• Remove the fan.
iMac (USB 2.0) Take Apart - 75
• Remove the fan bracket under the fan.
• Remove the neck spoke retainer cap.
• Remove the blind mate connector screws.
• Remove the Faraday cage.
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Antenna, Wireless

Procedure

1. Remove the mounting screw and unclip the board from the Faraday cage. Remove any tape, and carefully separate the antenna board cable from the Faraday cage.
2. Remove the second mounting screw to unclip the antenna from the Faraday cage.
Antenna, Wireless
iMac (USB 2.0) Take Apart - 77
Warning: Whenever the bottom housing is opened for service, you must do two things:
1.You must clean the original thermal film from all thermal interface mating surfaces, and reapply thermal paste to the mating surfaces on the thermal pipe.
2. You must tighten the four torx screws on the bottom housing to a minimum of 17 in.-lbs. Use a torque driver (service tool 076-0899) to ensure that the thermal pipe is firmly mated with the top base. If you do not have a torque driver, you must make sure the screws are tightened by hand FIRMLY, BUT NOT FORCIBLY.
Failure to follow 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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Antenna, Wireless

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 optical drive door.
• Remove the fan.
• Remove the fan bracket under the fan.
Housing, Outer Shell, Plastic
iMac (USB 2.0) Take Apart - 79
• Remove the neck spoke retainer cap.
• Remove the blind mate connector screws.
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Housing, Outer Shell, Plastic

Procedure

1. Remove the two black screws that connect the neck to the base.
2. Carefully feed the neck cables through the hole on the vent cap shown below.
Housing, Outer Shell, Plastic
iMac (USB 2.0) Take Apart - 81
3. Next, carefully separate the outer plastic housing from the neck.
4. Remove one screw in the base of the Faraday cage to separate the white outer shell from the Faraday cage.
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Housing, Outer Shell, Plastic
Warning: Whenever the bottom housing is opened for service, you must do two things:
1.You must clean the original thermal film from all thermal interface mating surfaces, and reapply thermal paste to the mating surfaces on the thermal pipe.
2. You must tighten the four torx screws on the bottom housing to a minimum of 17 in.-lbs. Use a torque driver (service tool 076-0899) to ensure that the thermal pipe is firmly mated with the top base. If you do not have a torque driver, you must make sure the screws are tightened by hand FIRMLY, BUT NOT FORCIBLY.
Failure to follow these steps could cause the computer to overheat and damage internal components.
Refer to the topic “Thermal Paste Application” for detailed information.
Housing, Outer Shell, Plastic
iMac (USB 2.0) Take Apart - 83

Display, 17" Flat Panel

Tools

This procedure requires the following tools:
• 1.5 mm hex tool
• Torx-10 screwdriver
Important: If you are replacing the 17-inch display panel, be sure to install the display shield and EMI gaskets that come with the new LCD panel. Installation instructions are included with the new display panel.

Part Location

Preliminary Steps

Before you begin, do the following:
• Position the computer in the service stand.
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Display, 17" Flat Panel

Procedure

1. Remove three screws that connect the back cover to the flat panel LCD display. Use the 1.5 mm hex tool to remove these screws.
2. Support the back cover and push on the display bezel (as shown) to separate the display bezel from the display’s back panel.
Display, 17" Flat Panel
iMac (USB 2.0) Take Apart - 85
3. Carefully raise the top side of the display and disconnect the inverter cable (A) and remove the tape holding down the TMDS cable (B).
4. Raise the display a bit more to access the TMDS displa y connector located behind the black tape. Peel back the black tape.
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Display, 17" Flat Panel
5. Disconnect the TMDS display connector by squeezing the clip (1) on each side of the connector. Gently pull the cable (2) out of the slot.
6. Raise the panel all the way up. Disconnect the power on LED cable (A) and the microphone cable (B). Set the rear housing/shield aside.
Display, 17" Flat Panel
iMac (USB 2.0) Take Apart - 87
7. Remove four screws that connect the LCD display panel to the display bezel. Also, remove the kapton tape to release the inverter cables on the left side, and the LED and microphone cables from the bottom edge of the LCD display.
8. Lift the display panel out of the display bezel.
9. Remove the inverter from the display if you are returning the flat panel display to Apple. Refer to the “Inverter, 17" Display” take apart procedure in this chapter for instructions. Replacement Note: If you are replacing the display, be sure to install the display shield and EMI gaskets (076-0958) that come with the new LCD panel. Installation instructions are included with the new display panel.
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Display, 17" Flat Panel
Replacing the 17"Display Panel
1. After connecting the display cables, position the display into the rear housing. Place the display into the rear housing, sliding it into position, pushing it in the direction of the arrows. Note: The display mates with tabs/slots in the rear housing. If the display doesn’t fit properly and you can’t install the three screws along the bottom of the housing, check that the display is properly seated in the rear housing.
2. Holding onto the display, turn it over and lay the display face down on a soft cloth. Push the rear housing in the direction of the arrows. This will mate the housing and display tabs.
Display, 17" Flat Panel
iMac (USB 2.0) Take Apart - 89
3. Check the alignment of the rear housing and the flat panel display. If the display doesn’t slide into the tabs/slots on the rear housing, a white line shows across the back of the rear housing (see below).
4. A properly installed display will have no white line sho wing across the bac k of the rear housing (see below), and the three display-to-housing screw holes align perfectly.
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Display, 17" Flat Panel

Display, 15" Flat Panel

Tools

This procedure requires the following tools:
• 1.5 mm hex tool
• Plastic stylus to lift the panel

Part Location

Preliminary Steps

Before you begin, do the following:
• Position the computer in the service stand.
Display, 15" Flat Panel
iMac (USB 2.0) Take Apart - 91
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