Apple Mac mini 05-12 Service Manual

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Service Source

Mac mini

Updated 6 December 2005

What’s New (July 2005)

• 512 MB DDR SDRAM standard on all units

• On the better and best configurations, the wireless AirPort Extreme card and Bluetooth board are now built-in

What’s New (September 2005)

• 1.33GHz or 1.5GHz G4 processor

• Faster hard drive

• 8x double-layer SuperDrive

• AirPort Extreme and Bluetooth 2.0+EDR (Enhanced Data Rate)

Visual Differences

There is a new mezzanine board (shown below in the middle) used with the AirPort Extreme/Bluetooth combo card (shown on the left). The antennas, also shown below, connect to the combo card, which connects to the mezzanine board. Refer to the topic: “Antennas, Mezzanine Board, AirPort Extreme/Bluetooth Card” in the Take Apart chapter for details.

Mac mini

Mac mini -

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Service Source

Take Apart

Mac mini

General Information

Tools

The following tools are required to service the computer:

• ESD wriststrap and mat

• Jeweler’s #0 Phillips screwdriver

• Jeweler’s #1 Phillips screwdriver

• Phillips #2 screwdriver

• Black stick (922-5065), or other nonconductive nylon or plastic tool

• Needlenose pliers

• Soft cloth (to protect removed parts from scratches)

• Screw tray

• Putty knife (922-6761),1.5 inch (38 mm), flexible blade

General Information

Mac mini Take Apart -

Modify the Putty Knife

1. If you don’t order a modiﬁed putty knife (922-6761) from Apple Service, purchase a

putty knife with a 1.5-inch (38 mm), ﬂexible metal blade.

2. Using sandpaper (150 grit), ﬁle down the end of the putty knife (on one side) until it’s

slightly beveled. Rub the edge of the putty knife back and forth for about 2 minutes on the sandpaper.

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General Information

Serial Number Location

The product serial number and Ethernet ID are located on the bottom housing.

General Information

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Thermal Pad

The thermal pad is located on the bottom housing. A new thermal pad is included with the logic board and the bottom housing, and the pads can be ordered separately as a kit (part number 922-6749).

Replace the pad when:

• the logic board or the bottom housing is replaced

• the pad is torn, withered, or damaged

Important:

thermal pad with a new identical pad.

Never use thermal paste in place of the thermal pad. You must replace the

Procedure

1. Remove the original pad from the bottom housing or the logic board using a black stick

or other nonconductive nylon tool.

2. Remove the protective backing on the new thermal pad.

contact with either side of the thermal pad as dirt and body oils reduce the thermal pad's conductivity.

3. Place the new thermal pad on the bottom housing (as shown). Make sure the thermal

pad has even contact with the bottom housing. There should be no air pockets.

Note:

Avoid unnecessary

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4. Replace the logic board.

General Information

Top Housing

Tools

The only tool required for this procedure is a modiﬁed putty knife (part number 922-6761)

Preliminary Steps

1. Shut down the computer.

Warning:

internal components or the components you are installing. Do not open the computer or attempt to install items inside it while it is on.

2. Unplug all external cables from the computer except the power cord.

3. Touch the metal case to discharge any static electricity from your body.

Important:

components inside the computer. To avoid generating static electricity, do not walk around the room until you have finished working and closed the computer.

4. Unplug the power cord.

5. Put on an ESD wrist strap.

Always shut down the computer before opening it to avoid damaging its

Always discharge static before you touch any parts or install any

Top Housing

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Removal Procedure

Caution:

1. Place the computer on a clean, ﬂat surface.

2. Turn the computer over so the ports are facing you and the bottom of the computer

3. Hold the putty knife with the beveled edge facing the bottom housing. Insert the tool

To avoid scratching the case, use caution when using the putty knife.

(gray color) is facing up.

into the gap where the metal housing and the bottom assembly come together on the left side of the computer. top or bottom housing when inserting the tool

Important:

Be extremely careful not to scratch or dent the

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Top Housing

4. Gently release the internal latches by prying the tool away from the computer.

Note:

You will hear little popping sounds as the latches release and the bottom

moves away from the top housing, creating a gap at the top of the I/O panel.

5. Be careful not to damage the EMI foam on the inside of the top cover.

Top Housing

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6. Repeat the procedure on the right side of the unit.

7. Push the I/O panel upward until the top housing is removed. The popping sounds will

continue as you push the I/O panel; this is normal.

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Top Housing

8. Set the top housing aside.

Top Housing

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Replacement Procedure

1. Align the rear I/O panel with the top housing. Make sure all the white latches on the

sides of the unit are aligned as shown in the photo below.

2. Squeeze the unit together ﬁrmly as shown. Proceed to the next step.

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Top Housing

3. If the computer doesn’t go together, check the EMI tab alignment (outlined below) and

try again. Check that the metal tabs aren’t bent.

Work your hands around the unit squeezing the top and bottom until they snap together and there are no gaps.

Top Housing

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AirPort Antenna and AirPort Extreme Card

Tools

This procedure requires the following tools:

• Black stick (or other nonconductive nylon or plastic tool)

• Jeweler’s #0 Phillips screwdriver

• Kapton tape

Preliminary Steps

Before you begin, remove the top housing.

Part Location

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AirPort Antenna and AirPort Extreme Card

Removal Procedure

1. Locate the AirPort antenna.

2. Using a black stick, push the black latch (see inset) toward the I/O ports to release the

antenna from the internal frame.

AirPort Antenna and AirPort Extreme Card

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4. Carefully lift the antenna up and off the internal frame. Free the antenna from the

kapton tape (circled). warped antenna will affect AirPort connectivity.

Important:

Take care handling the AirPort antenna as a bent or

5. Set the AirPort antenna off to the side.

cable are connected to the mezzanine board located under the internal frame.

Note:

The AirPort Extreme card and antenna

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AirPort Antenna and AirPort Extreme Card

6. Locate the Bluetooth antenna.

7. Pull the Bluetooth antenna up and out of the openings on the plastic rail. Free the

antenna cable from the kapton tape. antenna as a bent or warped antenna will affect Bluetooth connectivity.

Important:

Take care handling the Bluetooth

AirPort Antenna and AirPort Extreme Card

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8. Set the Bluetooth antenna off to the side and out of the way.

board is connected to the mezzanine board located under the internal frame.

Note:

The Bluetooth

9. Free the power button cable from the kapton tape on the internal frame.

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AirPort Antenna and AirPort Extreme Card

10. With a jeweler’s # 0 Phillips screwdriver, remove 3 screws on the internal frame.

11. Lift the internal frame straight up.

AirPort Antenna and AirPort Extreme Card

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12. Gently guide the Bluetooth and Airport antenna cables down through the opening in

the internal frame.

13. Set the internal frame aside.

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AirPort Antenna and AirPort Extreme Card

14. Locate the mezzanine board on the logic board.

15. To access the AirPort Extreme card remove the two screws on the mezzanine board

with a jeweler’s # 0 Phillips screwdriver. Pull the mezzanine board straight up and off the logic board connector.

AirPort Antenna and AirPort Extreme Card

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16. Turn over the mezzanine board. With your ﬁngernail or black stick, remove the AirPort

antenna cable (circled) from the AirPort Extreme card. Remove the kapton tape that secures the card to the mezzanine board. Pull the AirPort Extreme card out of the connector on the mezzanine board.

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AirPort Antenna and AirPort Extreme Card

Replacement Procedure

1. Install the AirPort Extreme card into the connector on the mezzanine board and

replace the kapton tape as shown. Plug the AirPort antenna cable into the opening on the end of the AirPort Extreme card.

2. Turn over the mezzanine board so the AirPort Extreme card is facing down. Connect

the mezzanine board to the connector on the logic board. Replace the two screws on the mezzanine board.

AirPort Antenna and AirPort Extreme Card

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3. Make sure that the AirPort antenna cable is ﬁrmly inserted into the AirPort Extreme

card. If the connector is not fully inserted, you’ll see a large portion of the connector collar. For details see Knowledge Base article 108039, “Properly attaching the antenna on an AirPort Extreme card.”

4. Hold the internal frame over the logic board as shown. Route the AirPort and

Bluetooth antenna cables up through the opening in the internal frame.

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AirPort Antenna and AirPort Extreme Card

5. Lower the internal frame into place.

of the internal frame.

Note:

Route the power button cable out of the way

6. Route the antenna cables to the right side of the interconnect board on the internal

frame as you continue lowering the internal frame onto the logic board.

AirPort Antenna and AirPort Extreme Card

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7. Replace the three screws on the internal frame.

8. Replace the Bluetooth antenna. Secure the antenna cable with kapton tape.

Important:

will affect Bluetooth connectivity.

Take care handling the Bluetooth antenna as a bent or warped antenna

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AirPort Antenna and AirPort Extreme Card

9. Replace the AirPort Extreme antenna. Secure the cable with kapton tape.

Important:

will affect AirPort connectivity.

Take care handling the AirPort antenna as a bent or warped antenna

10. Gently fasten the antenna onto the internal frame. The antenna is held in place by the

black clip and black post (shown below).

AirPort Antenna and AirPort Extreme Card

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11. Secure the power button cable to the internal frame with the kapton tape.

12. Replace the top housing.

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AirPort Antenna and AirPort Extreme Card

Bluetooth Antenna and Bluetooth Board

Tools

This procedure requires the following tools:

• Black stick (or other nonconductive nylon or plastic tool)

• Jeweler’s #0 Phillips screwdriver

• Kapton tape

Preliminary Steps

Before you begin, remove the top housing.

Part Location

Bluetooth Antenna and Bluetooth Board

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