Sony Ericsson S500 User manual

Working Instruction, Mechanical
3/000 21-1/FEA 209 544/603 A
Company Internal ©Sony Ericsson Mobile
Communications AB
Working Instruction, Mechanical
Applicable for S500, W580
CONTENTS
1Introduction ..............................................................................3
1.1 Tools and Equipment...............................................................4
1.2 General Cautions......................................................................5
1.3 Adhesives .................................................................................5
1.4 Using Hand and ESD Protection.............................................5
1.5 Protection of Displays, Lenses, and Windows......................5
1.6 Acceptable Pry Tools...............................................................5
2Disassembly .............................................................................6
2.1 Overview ...................................................................................6
2.1.1 Battery Cover Removal.........................................................7
2.1.2 Battery Removal....................................................................7
2.1.3 Label Removal ......................................................................8
2.1.4 Front Cover Removal............................................................9
2.1.5 Front Cover Removal Continued.........................................10
2.1.6 Navigation Keypad Removal...............................................10
2.1.7 Camera Cover Removal......................................................11
2.1.8 Front Cover Screws (6) Removal........................................12
2.1.9 Front Frame Removal .........................................................13
2.1.10 Front Frame Removal Continued........................................14
2.1.11 Upper Rear Cover Removal................................................14
2.1.12 Rear Frame Screws (4) Removal........................................15
2.1.13 Chin Cover Removal...........................................................16
2.1.14 Microphone Gasket Removal..............................................16
2.1.15 Rear Frame Removal from Hinge Assembly.......................17
2.1.16 Power Key Removal............................................................18
2.1.17 Bluetooth Tape....................................................................18
2.1.18 PC Board and Antenna Removal ........................................19
3Part Replacement...................................................................20
3.1 Bluetooth Antenna.................................................................20
3.2 Coaxial Cable and PC Board.................................................21
3.3 Coaxial Cable and Antenna...................................................22
3.4 System Connector..................................................................23
3.5 Volume Key.............................................................................24
3.6 LCD Assembly........................................................................25
3.7 LCD Assembly Continued.......................................................26
3.8 Bonzer Flex (Keypad Flex / Speaker Box Assembly) .........27

Working Instruction, Mechanical
3/000 21-1/FEA 209 544/603 A
©Sony Ericsson Mobile Communications AB 2(58)
3.9 Bonzer Flex (Keypad Flex / Speaker Box Assy) Cont.........28
3.10 Bonzer Flex (Keypad Flex / Speaker Box Assy) Cont.........29
3.11 Camera ....................................................................................30
3.12 Camera Continued...................................................................31
3.13 Memory Stick Cover...............................................................32
3.14 Memory Stick Cover Continued .............................................33
3.15 Receiver and Gasket..............................................................34
3.16 Microphone.............................................................................35
3.17 Microphone Continued............................................................36
3.18 Keypad ....................................................................................37
3.19 Wear Strips .............................................................................38
3.20 Vibrator....................................................................................39
3.21 Main Keypad Flex...................................................................40
3.22 Main Keypad Flex Continued..................................................41
3.23 Main Keypad Flex Continued..................................................42
3.24 Liquid Intrusion Indicator......................................................43
4Rear Frame / Pad....................................................................43
5Front Frame ............................................................................44
6Reassembly ............................................................................45
6.1 Overview .................................................................................45
6.1.1 PC Board and Antenna Installation .....................................46
6.1.2 PC Board and Antenna Installation Continued....................47
6.1.3 Power Key Installation.........................................................47
6.1.4 Bluetooth Tape Installation..................................................48
6.1.5 Rear Frame and Hinge Assembly Installation .....................49
6.1.6 Microphone Gasket Installation...........................................50
6.1.7 Chin Cover Installation........................................................51
6.1.8 Rear Frame Screws Installation ..........................................51
6.1.9 Upper Rear Cover Installation.............................................52
6.1.10 Front Frame Installation ......................................................53
6.1.11 Front Frame Installation Continued.....................................54
6.1.12 Camera Cover Installation...................................................55
6.1.13 Navigation Keypad Installation............................................56
6.1.14 Front Cover Installation.......................................................56
6.1.15 Label Installation .................................................................57
6.1.16 Battery Installation...............................................................57
6.1.17 Battery Cover Installation....................................................58
7Revision History.....................................................................58

Working Instruction, Mechanical
3/000 21-1/FEA 209 544/603 A
Company Internal ©Sony Ericsson Mobile
Communications AB
1 Introduction

Working Instruction, Mechanical
3/000 21-1/FEA 209 544/603 A
Company Internal ©Sony Ericsson Mobile
Communications AB
1.1 Tools and Equipment
The following tools and equipment should be available while performing the procedures.
STANDARD TOOLS
•Style 2A Tweezers – Rounded Tip
•Nylon Pointer
•Torque Driver
•Dental Hook
•Plectrum
PRODUCT SPECIFIC TOOLS
•Coaxial Cable Removal Tool
•Japanese Standard Torque Bit
ESD EQUIPMENT
Protect the phone from ESD damages whenever it has
been opened by using:
•ESD-wristband
•ESD-gloves
LABEL EQUIPMENT
The following special equipment is required when replacing
or installing a new label:
•Hot air device
•Zebra printer connected to computer

Working Instruction, Mechanical
3/000 21-1/FEA 209 544/603 A
©Sony Ericsson Mobile Communications AB 5(58)
1.2 General Cautions
The following cautions are considered to be generic for all products and will not be repeated in the
Disassembly, Reassembly, and Replacements sections:
•SWITCH OFF THE PHONE AND REMOVE ANY MEMORY STICK BEFORE THE START OF THE DISASSEMBLY!
•KEEP ALL CONTACT SURFACES CLEAN!
•BE CAREFUL WHEN USING TOOLS LIKE THE DENTIST HOOK,TWEEZERS,PRY TOOLS,ETC.TO AVOID
SCRATCHES OR DAMAGE TO THE EXTERIOR AND INTERIOR PARTS OF THE PHONE!
•BE CAREFUL NOT TO DAMAGE ANY CONTACT SPRINGS!
•REMEMBER TO REMOVE THE PROTECTION FILMS ON NEW PARTS SUCH AS THE FRONT COVER AND LCD!
•NEVER TOUCH THE DISPLAY GLASS!
1.3 Adhesives
Use a dentist hook, the tweezers, and/or a nylon pointer to remove old adhesives.
Clean the surface with isopropyl alcohol before attaching new adhesives.
1.4 Using Hand and ESD Protection
When handling this product, keep all surfaces clean of dirt, dust, debris, and hand oil. Use
appropriate ESD precautions when working on this product. The use of finger cots or gloves, an ESD
mat, and an ESD wrist strap are required at minimum.
1.5 Protection of Displays, Lenses, and Windows
Any time the screen portion of a display assembly, the windows of a display cover, or a camera lens
is unprotected and exposed, add a protective film over the exposed part to reduce the amount of
dust, finger prints, debris, and/or damage that the part may obtain.
1.6 Acceptable Pry Tools
Whenever the phrase “pry tool” is used, a nylon pointer or a front opening tool may be used
depending on the user’s preference.

Working Instruction, Mechanical
3/000 21-1/FEA 209 544/603 A
Company Internal ©Sony Ericsson Mobile
Communications AB
2 Disassembly
2.1 Overview
Perform the disassembly in the following order:
Slider – Top Section
•Remove Battery Cover (1)
•Remove Battery (2)
•Remove Label (3)
•Remove Front Cover (4)
•Remove Navigation Keypad (5)
•Remove Camera Cover (6)
•Remove 6 Front Cover Screws (not shown)
•Separate Front Frame (7) and Rear Frame / Hinge
Assembly (8)
Base – Bottom Section
•Remove Upper Rear Cover (1)
•Remove 4 Rear Frame Screws (not shown)
•Remove Chin Cover (2)
•Remove Microphone Gasket (3)
•Remove Rear Frame (4) from Hinge Assembly (8)
•Remove Bluetooth Tape (5)
•Remove Power Key (6)
•Remove Board and Antenna (7)

Working Instruction, Mechanical
3/000 21-1/FEA 209 544/603 A
©Sony Ericsson Mobile Communications AB 7(58)
2.1.1 Battery Cover Removal
Use thumbs to push the battery cover down until it stops.
Lift the end of the battery cover to remove it.
2.1.2 Battery Removal
Use a finger to lift the battery up.

Working Instruction, Mechanical
3/000 21-1/FEA 209 544/603 A
©Sony Ericsson Mobile Communications AB 8(58)
Pull the battery out of the battery cavity.
2.1.3 Label Removal
Apply hot air to soften the adhesive.
NOTE: THE USE OF HOT AIR IS OPTIONAL.
Use a pry tool or tweezers to begin peeling up the label.
Use tweezers to finish pulling the label off.
NOTE: BE CAREFUL WHEN PULLING THE LABEL OFF
THE FLEX CONNECTOR.

Working Instruction, Mechanical
3/000 21-1/FEA 209 544/603 A
©Sony Ericsson Mobile Communications AB 9(58)
2.1.4 Front Cover Removal
Insert the plectrum between the front cover and the frame at
the bottom side of the volume key.
Slide the plectrum toward the top corner to release the
latch.
Continue around the cover to release the other corner latch.
Slide the plectrum down the other side to release the side
latch.

Working Instruction, Mechanical
3/000 21-1/FEA 209 544/603 A
©Sony Ericsson Mobile Communications AB 10(58)
2.1.5 Front Cover Removal Continued
Rotate the cover up a small amount, and then slide it down
and off of the frame.
NOTE: DO NOT ROTATE THE COVER TOO FAR OR
THE BOTTOM PEGS WILL BE DAMAGED.
2.1.6 Navigation Keypad Removal
Remove navigation keypad from front cover.

Working Instruction, Mechanical
3/000 21-1/FEA 209 544/603 A
©Sony Ericsson Mobile Communications AB 11(58)
2.1.7 Camera Cover Removal
Locate the two tabs that hold the camera cover in place.
Use a pry tool to bend the metal tabs up.
Insert a pry tool between the cover and the frame to pry the
cover up.
Remove the cover.

Working Instruction, Mechanical
3/000 21-1/FEA 209 544/603 A
©Sony Ericsson Mobile Communications AB 12(58)
2.1.8 Front Cover Screws (6) Removal
Slide the hinge into the open position, and then use a
torque wrench and a JCIS-0 bit to remove the 4 visible
screws.
NOTE: DO NOT REUSE THE SCREWS.
Use the magnetism of the wrench to pull the bottom screws
up through the hole in the hinge.
Slide the hinge partially closed until the remaining 2 screws
are visible.
While holding the hinge in the partially closed position,
remove the screws.
NOTE: DO NOT REUSE THE SCREWS.

Working Instruction, Mechanical
3/000 21-1/FEA 209 544/603 A
©Sony Ericsson Mobile Communications AB 13(58)
2.1.9 Front Frame Removal
Use a pry tool to release the metal latch of the hinge from
the Front Frame.
Slide the hinge to the closed position enough to release the
metal hook.
Release the metal hook on the other side also.
Rotate the bottom of the Front Frame to the side enough to
release the other metal latch.

Working Instruction, Mechanical
3/000 21-1/FEA 209 544/603 A
©Sony Ericsson Mobile Communications AB 14(58)
2.1.10 Front Frame Removal Continued
Use a pry tool to disconnect the Front Frame connector.
Remove the Front Frame from the hinge.
2.1.11 Upper Rear Cover Removal
Insert a pry tool between the rear cover and the rear frame.

Working Instruction, Mechanical
3/000 21-1/FEA 209 544/603 A
©Sony Ericsson Mobile Communications AB 15(58)
Rotate or twist the tool until the rear cover latch releases.
Use finger to pull up the rear cover and release the other
latches.
Pull the rear cover down and out of the rear frame.
2.1.12 Rear Frame Screws (4) Removal
Use a torque wrench and a JCIS-0 bit to remove the 4
screws.
NOTE: DO NOT REUSE THE SCREWS.

Working Instruction, Mechanical
3/000 21-1/FEA 209 544/603 A
©Sony Ericsson Mobile Communications AB 16(58)
2.1.13 Chin Cover Removal
Insert the plectrum between the keypad and the left end of
the chin cover.
Use fingers to remove the chin cover.
2.1.14 Microphone Gasket Removal
Remove the microphone gasket from the hinge assembly.

Working Instruction, Mechanical
3/000 21-1/FEA 209 544/603 A
©Sony Ericsson Mobile Communications AB 17(58)
2.1.15 Rear Frame Removal from Hinge Assembly
With the slider open and the keypad up, locate the metal
clip of the hinge.
Insert tweezers or small screwdriver under the metal clip
and twist toward the center of the phone to release the
latch.
Separate the frame from the hinge.
Repeat the process on the other side of the phone.

Working Instruction, Mechanical
3/000 21-1/FEA 209 544/603 A
©Sony Ericsson Mobile Communications AB 18(58)
Use a pry tool to unplug the connector.
2.1.16 Power Key Removal
Use tweezers to remove the power key.
2.1.17 Bluetooth Tape
Use tweezers to remove the Bluetooth tape.

Working Instruction, Mechanical
3/000 21-1/FEA 209 544/603 A
©Sony Ericsson Mobile Communications AB 19(58)
2.1.18 PC Board and Antenna Removal
Use a pry tool to release the board from the latches beside
the SIM connector.
Remove the antenna from the slot on the rear frame.
Remove the board, coaxial cable, and antenna.

Working Instruction, Mechanical
3/000 21-1/FEA 209 544/603 A
©Sony Ericsson Mobile Communications AB 20(58)
3 Part Replacement
3.1 Bluetooth Antenna
Remove the Upper Rear Cover as shown in the
Disassembly section.
Removal
Remove the Bluetooth antenna from the rear frame by
sliding it toward the edge of the frame.
Installation
Insert the bent pins of the antenna into the slots of the
frame.
Push the antenna into place.