Sony Ericsson Z525i User manual

Working Instruction, Mechanical
3/00021-1/FEA 209 544/597 F
©Sony Ericsson Mobile Communications AB
Working Instruction, Mechanical
Applicable for Z520a, Z520i, Z520c, Z525a, Z525i
Contents
1General............................................................................................... 3
2Base ................................................................................................... 4
2.1 Base Disassembly................................................................. 4
2.1.1 Battery Cover Removal ....................................... 4
2.1.2 Battery Removal .................................................. 5
2.1.3 Outer Base Cover Removal................................. 6
2.1.4 Flip Assembly Removal ....................................... 8
2.1.5 Circuit Board Removal......................................... 9
2.2 Base Reassembly ............................................................... 10
2.2.1 Circuit Board Installation.................................... 10
2.2.2 Flip Assembly Installation .................................. 12
2.2.3 Outer Base Cover Installation............................ 14
2.2.4 Battery Installation ............................................. 17
2.2.5 Battery Cover Installation .................................. 18
3Flip.................................................................................................... 19
3.1 Flip Disassembly ................................................................. 19
3.1.1 Style-Up Cover Removal ................................... 19
3.1.2 Outer Flip Cover Removal ................................. 21
3.1.3 LCD Sub-Frame Removal ................................. 23
3.2 Flip Reassembly.................................................................. 24
3.2.1 LCD Sub-Frame Installation .............................. 24
3.2.2 Outer Flip Cover Installation .............................. 27
3.2.3 Style-Up Flip Cover Installation ......................... 31
4Part Replacement............................................................................ 32
4.1 Battery Cover ...................................................................... 32
4.2 Battery................................................................................. 32
4.3 Keypad ................................................................................ 32
4.3.1 Keypad Removal ............................................... 32
4.3.2 Keypad Installation ............................................ 33
4.4 Flip Bumper Strip ................................................................ 34
4.4.1 Flip Bumper Strip Removal................................ 34
4.4.2 Flip Bumper Strip Installation............................. 34
4.5 Inner Base Cover ................................................................ 35
4.6 Outer Base Cover ............................................................... 37
4.7 IR Window........................................................................... 38
4.8 RF Port Plug........................................................................ 40
4.8.1 RF Port Plug Removal....................................... 40
4.8.2 RF Port Plug Installation.................................... 41

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4.9 Style-Up Cover.................................................................... 42
4.10 Outer Flip Cover.................................................................. 43
4.11 Camera Ring ....................................................................... 46
4.12 Rubber Plugs that hold the Style-Up Cover ........................ 47
4.13 Vibrator................................................................................ 49
4.14 Co-Branded Bezel............................................................... 50
4.14.1 Co-Branded Bezel Removal .............................. 50
4.14.2 Co-Branded Bezel Installation ........................... 51
4.15 LCD Sub-frame ................................................................... 52
4.16 Flip Screw Covers ............................................................... 53
4.16.1 Flip Screw Cover Removal ................................ 53
4.16.2 Flip Screw Cover Installation ............................. 54
4.17 Antenna Cover .................................................................... 55
4.17.1 Antenna Cover Removal ................................... 55
4.17.2 Antenna Cover Installation ................................ 56
4.18 Antenna Assembly .............................................................. 58
4.18.1 Antenna Assembly Removal ............................. 58
4.18.2 Antenna Assembly Installation .......................... 59
4.19 Magnet ................................................................................ 60
4.19.1 Magnet Removal ............................................... 60
4.19.2 Magnet Installation ............................................ 60
4.20 LCD Assembly .................................................................... 61
4.20.1 LCD Assembly Removal.................................... 61
4.20.2 LCD Assembly Installation................................. 63
4.21 Camera Module................................................................... 66
4.21.1 Camera Module Removal.................................. 66
4.21.2 Camera Module Installation............................... 68
4.22 Camera Key ........................................................................ 70
4.23 PTT Key – Z525a and Z525i Only....................................... 70
4.24 Volume Key......................................................................... 71
4.24.1 Volume Key Removal ........................................ 71
4.24.2 Volume Key Installation ..................................... 72
4.25 Bluetooth Antenna............................................................... 73
4.25.1 Bluetooth Antenna Removal.............................. 73
4.25.2 Bluetooth Antenna Installation........................... 74
4.26 SEMC Icon .......................................................................... 75
4.26.1 SEMC Icon Replacement – If Damaged............ 75
4.26.2 SEMC Icon Replacement – If Missing ............... 75
4.27 Label ................................................................................... 76
4.27.1 Label Removal................................................... 76
4.27.2 Label Installation................................................ 77
4.28 Dome Foil............................................................................ 78
4.28.1 Dome Foil Removal ........................................... 78
4.28.2 Dome Foil Installation ........................................ 79
4.29 System Connector............................................................... 80
4.29.1 System Connector Removal.............................. 80
4.29.2 System Connector Installation........................... 80
4.30 Liquid Intrusion Indicator on System Connector ................. 82
4.31 Liquid Intrusion Indicator on Shield Can (Cingular Only) .... 82
4.32 Rear Speaker Cloth............................................................. 83
4.32.1 Rear Speaker Cloth Removal............................ 83

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4.32.2 Rear Speaker Cloth Installation......................... 85
4.33 Rear Speaker ...................................................................... 86
4.33.1 Rear Speaker Removal ..................................... 86
4.33.2 Rear Speaker Installation .................................. 87
4.34 Receiver .............................................................................. 89
4.34.1 Receiver Removal ............................................. 89
4.34.2 Receiver Installation .......................................... 90
4.35 Side Key Flex Film .............................................................. 92
4.35.1 Side Key Flex Film Removal ............................. 92
4.35.2 Side Key Flex Film Installation .......................... 93
4.36 Hinge................................................................................... 95
4.36.1 Hinge Removal .................................................. 95
4.36.2 Hinge Installation ............................................... 97
4.37 Main Flex Film................................................................... 100
4.37.1 Main Flex Film Removal .................................. 100
4.37.2 Main Flex Film Installation ............................... 103
4.38 Inner Flip Cover................................................................. 110
4.39 Co-Brand Label ................................................................. 114
4.39.1 Co-Brand Label Removal ................................ 114
4.39.2 Co-Brand Label Installation ............................. 114
5Revision History............................................................................ 115
1General
This document uses the hinge of the phone to divide the phone into two identifiable portions. The
portion of the phone that contains the keypad will be referred to throughout this document as the
base portion of the phone. The portion of the phone that contains the displays will be referred to as
the flip portion of the phone. The basic disassembly and reassembly procedures will be structured
based on these two distinct portions.
General Notes:
•When handling this product take care to keep all surfaces clean of dirt, dust, debris, and hand
grease. 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.
•Any time one of the screen portions of the display assembly, the window portion of the interior
flip cover, or the camera lens is unprotected and will be exposed in this unprotected fashion for
an extended period of time, a protective film should be added over the exposed part(s) to
reduce the amount of dust, finger prints, debris, and/or damage that the part(s) may obtain
during its period of exposure.
•The display tape that is attached to the edge of the LCD assembly to protect the camera flex
film is not shown in some of the pictures of sections that do not pertain to the verification
and/or installation of the display tape. Note that the display tape is required and should be
installed on the LCD assembly.

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2Base
2.1 Base Disassembly
The disassembly of the base portion of this product is broken down into sections by the
components that need to be removed to perform the disassembly. The sections that make up the
“Base Disassembly” procedure are arranged in the order that they must be performed to properly
disassemble the base portion of this product. If your task is to replace one of the components that
is removed during the base disassembly, just perform the sections of the base disassembly through
to the point that the part you are trying to replace is removed.
2.1.1 Battery Cover Removal
Tools needed to perform the following steps: •Front opening tool
Step-by-Step Instructions
1. Close the phone so that the keypad is not accessible.
2. Dislodge the battery cover from the outer base cover
by applying force downward and outward
simultaneously to the end of the battery door that is
nearest the system connector.
NOTE! The battery door can be very difficult to
remove. If the battery door will not move,
insert the angled tip of a front opening tool
into the seam where the battery cover and
the bottom edge of the speaker port come
together. Do not twist or rotate the front
opening tool once it is inserted. Just remove
the front opening tool and repeat step 2.

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Step-by-Step Instructions
3. Once dislodged, lift the battery cover away from the
phone.
2.1.2 Battery Removal
All of the sections of the Base Disassembly preceding this section must be performed in sequential
order before the disassembly steps listed below can be performed.
Tools needed to perform the following steps: •Pry Tool
NOTE! Whenever the phrase “pry tool” is used, a nylon pointer, an orangewood stick, or a front
opening tool may be used, depending on the user’s preference.
Step-by-Step Instructions
NOTE! Do not tap the phone against a hard surface
in an attempt to get the battery out. Damage
to the phone may result!
1. At the end of the battery closest to the hinge, catch
the flat end of a pry tool on the accessible portion of
the battery that is adjacent to the speaker port.
2. Using the pry tool, push the battery towards the
system connector while simultaneously lifting the
end of the battery. The end being lifted should come
free from the battery cavity.

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Step-by-Step Instructions
3. Once the end of the battery is free from the battery
cavity, lift the battery away from the phone.
2.1.3 Outer Base Cover Removal
All of the sections of the Base Disassembly preceding this section must be performed in sequential
order before the disassembly steps listed below can be performed.
Tools needed to perform the following steps:
•Torque screwdriver •T6 Torx® bit •Pry Tool
NOTE! Whenever the phrase “pry tool” is used, a nylon pointer, an orangewood stick, or a front
opening tool may be used, depending on the user’s preference.
Step-by-Step Instructions
1. With the phone closed, remove the four screws
indicated from the base portion of the phone using a
torque driver with a T6 Torx® bit.
2. Open the phone so that the keypad is accessible.

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Step-by-Step Instructions
NOTE! Be careful not to scratch the inner and outer
base cases when prying them apart.
3. On each side of the system connector, the inner and
outer base covers come together to form seams on
each side of the phone. Work the flat end of a pry
tool into one of the seams adjacent to the system
connector.
4. Using a method of sliding and twisting the pry tool,
separate the seam between the inner and outer base
covers until just before reaching the portion of the
inner base cover that conceals the hinge.
NOTE! Be very careful when performing the next
step over the camera key. Damage to the
side key flex film can occur.
5. Insert the flat end of the pry tool into the seam at the
point where inner base cover transitions into its
hinge concealing portion.
6. Gently rotate the pry tool towards the phone’s
keypad. The latch that is holding the inner base
cover in place should disengage from the outer base
cover.
NOTE! Some times repeating this step is required to
get the latch to disengage.
7. Repeat the four previous steps on the inner/outer
base cover seam that has not been separated.

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Step-by-Step Instructions
NOTE! The camera key falls out of its opening
when performing the next step.
8. Gently and slowly rotate the flip portion of the phone
away from the keypad until the inner portion of the
base separates from the outer base cover.
9. Locate the camera key and set it aside.
2.1.4 Flip Assembly Removal
All of the sections of the Base Disassembly preceding this section must be performed in sequential
order before the disassembly steps listed below can be performed.
Tools needed to perform the following steps: •Pry Tool
NOTE! Whenever the phrase “pry tool” is used, a nylon pointer, an orangewood stick, or a front
opening tool may be used, depending on the user’s preference.
Step-by-Step Instructions
1. Turn the flip/inner base assembly so that the side of
the circuit board with the SIM holder is upward.
2. Release the main flex film connection from the
circuit board using a pry tool.

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Step-by-Step Instructions
3. Once the main flex film is disconnected, lift up on
the flip assembly while pulling down on each side of
the inner base cover in the locations that are in line
with the screw bosses that protrude through the
board. The flip assembly, including the hinge and
the antenna cover should easily lift away from the
circuit board.
2.1.5 Circuit Board Removal
Tools needed to perform the following steps: None
Step-by-Step Instructions
1. Lift the circuit board from the inner base cover.

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2.2 Base Reassembly
The reassembly of the base portion of this product is broken down into sections by the components
that need to be installed to perform the reassembly of the base portion. The sections that make up
the “Base Reassembly” procedure are arranged in the order that they must be performed to
properly reassemble the base portion of this product. If you have only performed a partial
disassembly of the base, just perform the appropriate reassembly sections.
2.2.1 Circuit Board Installation
Tools needed to perform the following steps: None
Step-by-Step Instructions
1. Obtain the inner base cover that will be installed.
2. Inspect the portion of the inner base cover indicated
(Figure 1) using figures 2, 3, and 4 to determine if a
shim needs to be added.
a. If a shim is present (Figure 2) or if additional
material is present beside the opening in the side
wall (Figure3) proceed to step 3.

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Step-by-Step Instructions
b. If no additional material or shim is present
(Figure 4), add a shim as follows.
•Place the short side of the shim flush against
the edge of the wall labelled “A” and the
long side of the shim flush against the edge
of the wall labelled “B”.
•Apply pressure to the shim for 5 seconds
once it is positioned so that a good bond
forms.
NOTE! When the shim is correctly placed
the hole is the side wall is
completely covered.
3. Orient the inner base cover so its inner surface is
facing upward.
4. Verify that the flip bumper strip and the keypad are
present and correctly seated in the inner base cover
before proceeding. If either of the parts is not
present, install a new part for the component(s) that
is missing. Refer to the Part Replacement section of
this document for the specific part(s) that is missing
for instructions on how to correctly install either of
these parts.
5. Place the circuit board, dome foil side down, onto
the keypad so that the circuit board is seated down
against the inner surface of the inner base cover.

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2.2.2 Flip Assembly Installation
Tools needed to perform the following steps: None
Step-by-Step Instructions
1. Orient the flip assembly so that the large display is
facing downward.
2. Orient the circuit board/inner base cover assembly to
the flip assembly so that their hinge ends are towards
one another as shown.
3. Press the edge of the antenna cover that is furthest
from the hinge down towards the flip. This action
moves the two tab features on the antenna cover
against the two joints of the hinge, making it easier
to correctly assemble the two halves of the phone.
4. Locate the tab that is against each of the two joints
of the hinge assembly.
5. While continuing to lightly press the antenna cover
towards the flip, insert the antenna cover’s two tabs
behind their mating edges of the hinge covering
portion of the inner base cover.

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Step-by-Step Instructions
6. Once the tabs of the antenna cover are inside the
hinge concealing portion of the inner base cover,
rotate the flip assembly so that the hinge inserts into
the hinge covering portion of the inner base cover
and the arm of the hinge slides down over the two
screw bosses that protrude through the circuit board.
7. While holding the two halves of the phone together,
connect the main flex film to its connector on the
circuit board.

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2.2.3 Outer Base Cover Installation
If this part is being replaced, a new part should be used in the place of the old part and the
following bulleted actions should be preformed before performing the following procedure.
•Install a new IR window in the new outer base cover. Refer to IR window installation
section for detailed instructions.
•Transfer the antenna assembly, the side volume key, the Bluetooth antenna, and the RF
plug from the old outer base cover to the new one. Refer to the removal and installation
sections of any specific component whose removal and installation procedures are in
question.
•Create and install a new set of labels. Refer to label installation section for detailed
instructions.
Tools needed to perform the following steps:
•Torque screwdriver •T6 Torx® bit
Step-by-Step Instructions
1. Obtain the outer base cover and verify that the
antenna assembly, the Bluetooth antenna, and the
side volume key are in their correct positions.
NOTE! The camera key should not be present.
2. Orient the outer base cover so that its inner cavity is
upward, the side volume key is towards you, and the
cover is rotated at a slight downward angle to help
keep the side volume key in place.
3. While holding the flip/circuit board portion of the
phone over the outer base cover insert the side key
flex film into its slot behind the side volume key.
4. Rotate the flip/circuit board assembly on top of the
outer base cover and work the antenna cover’s “U”
shaped extension into the corresponding hole in the
antenna assembly.

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Step-by-Step Instructions
NOTE! The latch that is being referred to in the
following step is located directly below the
portion of the inner base cover that conceals
the hinge.
5. Snap into place the inner base cover’s latch that is
located on the side of the inner base cover that does
not contain side keys.
6. Slightly lift out of the way the portion of the inner
base cover that is above the camera key opening and
slide the camera key into its slot.
7. Snap into place the latch on the side of the inner base
cover that is adjacent to the camera key.
8. Finish snapping the inner and outer base covers
together by squeezing around the seam where the
two covers connect.
NOTE! Test the side volume key and camera key by
pressing each of them several times to make
sure that the response of each key feels
correct.

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Step-by-Step Instructions
9. Close the phone so that the keypad is not accessible.
10. Snap the external edge of the antenna cover into
position in the outer base cover.
11. Using a torque screwdriver set to 17 N·cm with a T6
Torx® bit, install the four 1.6 X 5.1mm screws
(black colored) into the outer base cover in the
following order.
a. First, insert a screw in the screw location
adjacent to the RF port.
b. Next, install a screw in the unoccupied screw
location that is adjacent to the rear speaker.
c. Finally, install a screw in each of the two
remaining screw locations that are near the
system connector.
12. Verify that a piece of tape is mounted on the shield
can adjacent to the SIM connector as shown. If there
is not a piece of tape in this location indicated install
a piece of display tape by:
•Centering the display tape with the
contacts of the SIM connector and
allowing the tape to slightly overlap the
edge of the shield can.
•Fold the tape’s overlap down onto the
shield can.
All of the sections of the base reassembly following this section must be performed in sequential
order to reassemble the base portion of the phone.

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2.2.4 Battery Installation
If this part is being replaced, a new part should be used in the place of the old part when the
following steps are being performed.
Tools needed to perform the following steps: None
Step-by-Step Instructions
1. With the label side of the battery oriented away from
the phone, insert the end of the battery with
connection pads into the end of the battery cavity
nearest the system connector.
2. While pushing the battery towards the system
connector, simultaneously press the other end of the
battery down into the battery cavity.
All of the sections of the base reassembly following this section must be performed in sequential
order to reassemble the base portion of the phone.

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2.2.5 Battery Cover Installation
Tools needed to perform the following steps: None
If this part is being replaced, a new part should be used in the place of the old part when the
following steps are being performed.
Step-by-Step Instructions
1. Place the battery cover over the battery so that the
tips at the top of the battery cover are above the
screw holes in the outer base cover that are on each
side of the speaker port.
2. Slide the battery cover towards the hinge until the
battery cover snaps into place.

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3Flip
3.1 Flip Disassembly
The disassembly of the flip portion of this product is broken down into sections by the components
that need to be removed to perform the disassembly. The sections that make up the “Flip
Disassembly” procedure are arranged in the order that they must be performed to properly
disassemble the flip portion. If your task is to replace one of the components that are removed
during the flip disassembly, just perform the sections of the flip disassembly through to the point
that the part you are trying to replace is removed.
3.1.1 Style-Up Cover Removal
Tools needed to perform the following steps: •Nylon Pointer
Step-by-Step Instructions
1. Locate the two notches found along the seam where
the style-up cover and the outer flip cover come
together. Select one of the notches as your start
point.
2. On the side of the phone that your selected notch is
located, apply pressure to the outer surface of the
style-up cover about 0.75 inches from the non-hinge
end of the phone, so that the style-up cover is being
pressed against the outer flip cover.
3. Using your selected notch as an entry point, insert the
flat end of a nylon pointer into the seam of the style-
up cover so that approximately 1MM of the nylon
pointer’s tip is under the edge of the style-up cover.

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Step-by-Step Instructions
4. Slide the pry tool along the seam just before reaching
the location where the style-up cover is being pressed
and rotate the nylon pointer towards the base so that
the latch holding the style up cover disengages. Stop
pressing once the latch disengages.
5. Locate the other notch found along the seam where
the style-up cover and the outer flip cover come
together and repeat the previous three steps to release
that side of the style-up cover from the phone.
6. Once the two side latches are free, pry the hinge end
of the style-up cover loose from the press-fit sockets
that are holding it.
7. Remove the style-up cover by rotating it away from
the hinge joint while simultaneously lifting the cover
from the phone.