Sony Xperia ZL User manual

1271-7733 Rev 2

Sony Mobile Communications AB – Company Internal
Working Instructions
- mechanical -
Xperia
TM
ZL
C6502, C6503, C6506 & L35h

Working Instruction (mech)
1271-7733 Rev 2

Sony Mobile Communications AB – Company Internal
2(76)
CONTENTS
1Exterior Views................................................................................. 4
2Tools ................................................................................................ 5
3Disassembly.................................................................................... 7
3.1 Back Cover Assy.................................................................................. 8
3.2 Disconnect battery............................................................................... 9
3.3 Clip USB................................................................................................ 9
3.4 Carrier Spbox ..................................................................................... 10
3.5 PBA Complete Assy........................................................................... 11
3.6 Ant NFC............................................................................................... 13
4Replacement ................................................................................. 14
4.1 Back Cover Assy................................................................................ 14
4.2 Clip USB.............................................................................................. 14
4.3 Carrier Spbox Assy ............................................................................ 14
4.4 PBA Complete Assy........................................................................... 15
4.5 Front Assy Unit .................................................................................. 15
4.6 Adhesive Backcover .......................................................................... 16
4.7 Adhesive Battery................................................................................ 17
4.8 Adhesive Label................................................................................... 18
4.9 Adhesive Vibrator .............................................................................. 19
4.10 Adhesive Vibrator Wire...................................................................... 20
4.11 Ant NFC............................................................................................... 21
4.12 Attachment Power Key ...................................................................... 23
4.13 Back Cover ......................................................................................... 24
4.14 Battery 2300 mAh............................................................................... 25
4.15 Battery Grounding.............................................................................. 27
4.16 Camera 13 MP..................................................................................... 28
4.17 Camera 2.2 MP.................................................................................... 29
4.18 Carrier Antenna .................................................................................. 30
4.19 Carrier Sidekey................................................................................... 31
4.20 Carrier Spbox ..................................................................................... 33
4.21 Carrier Ear Piece Holder .................................................................... 34
4.22 Clip USB.............................................................................................. 35
4.23 Cover Card.......................................................................................... 36
4.24 Earspeaker.......................................................................................... 37
4.25 FPC AVP ............................................................................................. 38
4.26 FPC Camera key PBA ........................................................................ 39
4.27 FPC Side Key...................................................................................... 40
4.28 Front Assy .......................................................................................... 41
4.29 Gasket Battery FPC Support ............................................................. 42

Working Instruction (mech)
1271-7733 Rev 2

Sony Mobile Communications AB – Company Internal
3(76)
4.30 Gasket Proximity................................................................................ 43
4.31 Gasket Vibrator .................................................................................. 44
4.32 Grommet AVP..................................................................................... 45
4.33 Key Camera ........................................................................................ 46
4.34 Key Power........................................................................................... 47
4.35 Key Volume ........................................................................................ 48
4.36 Label Mobile Phone............................................................................ 49
4.37 Mic Protection Tape ........................................................................... 50
4.38 Panel Bottom ...................................................................................... 51
4.39 Panel Side Left ................................................................................... 52
4.40 Panel Side Right 1.............................................................................. 53
4.41 Panel Side Right 2.............................................................................. 54
4.42 Panel Top............................................................................................ 55
4.43 PBA Complete .................................................................................... 56
4.44 Shield Can Chat Camera.................................................................... 57
4.45 Silicon Camera Key............................................................................ 58
4.46 Silicon Power Key .............................................................................. 59
4.47 Silicon Volume Key............................................................................ 60
4.48 WI Bottom ........................................................................................... 61
4.49 WI Top ................................................................................................. 62
4.50 Vibrator ............................................................................................... 63
4.51 Board Swap - Replacement ............................................................... 64
4.52 Board Swap – Change Label ............................................................. 65
4.53 Board Swap – Customize of Software .............................................. 66
5Re-Assembly................................................................................. 67
5.1 Ant NFC............................................................................................... 68
5.2 PBA Complete Assy........................................................................... 69
5.3 Carrier Spbox Assy ............................................................................ 72
5.4 Clip USB.............................................................................................. 73
5.5 Connect battery.................................................................................. 73
5.6 Back Cover Assy................................................................................ 74
6Revision History ........................................................................... 76
For general information about mechanical repair related issues, refer to
1220-1333: Generic Repair Manual - mechanical

Working Instruction (mech)
1271-7733 Rev 2

Sony Mobile Communications AB – Company Internal
4(76)
1 Exterior Views

Working Instruction (mech)
1271-7733 Rev 2

Sony Mobile Communications AB – Company Internal
5(76)
2 Tools
SPECIAL TOOLS
1. Torque Screwdriver
2. Front Opening Tool
3. Bits (JCIS No 0)
4. Flex Film Assembly Tool
5. Guitar Pick
6. Nylon pointer
7. Battery Connector Removal Tool
8. Dentist hook
9. Battery Removal Tool
10. Backcover Adhesive alignment fixture
11. Backpanel press Top Inlay
12. Battery press Top Inlay
13. Bottom Press Inlay
For part not on the tools above, refer to the ‘Tools Catalogue/Matrix’!

Working Instruction (mech)
1271-7733 Rev 2

Sony Mobile Communications AB – Company Internal
6(76)

Working Instruction (mech)
1271-7733 Rev 2

Sony Mobile Communications AB – Company Internal
7(76)
3 Disassembly
The Disassembly is done to the following modules:
1. Back Cover Assy*
2. Clip USB
3. Carrier Spbox Assy*
4. PBA Complete Assy*
5. Front Assy Unit*
6. Ant NFC
*) Assy and Unit is used when several parts are handled
1
2
3
5
6
4

Working Instruction (mech)
1271-7733 Rev 2

Sony Mobile Communications AB – Company Internal
8(76)
Disassembly
3.1 Back Cover Assy
Open the Cover Card.
SIM card and Memory Card needs to be removed!
Unfold the label to remove the 2 Screw 3.0 by using a
screwdriver with Bits (JCIS No 0).
Scrap! Not to be reused!
Insert a Guitar Pick as shown in picture loosen the adhesive
along the right side according to the picture.
Unlatch the 3 snaps with a Guitar pick.
Stop at the red line (5mm below the Flash LED) to avoid
damage on hidden flex!
Gently break open the Back Cover Assy with a counter
clockwise movement.
Gently rub with a Nylon Pointer to remove the Adhesive
Backcover.
Remove and clean any remaining adhesive residue
found on Back Cover Assy and Front Assy Unit

Working Instruction (mech)
1271-7733 Rev 2

Sony Mobile Communications AB – Company Internal
9(76)
Disassembly
3.2 Disconnect battery
Use the Battery Connector Removal Tool to remove the BtB
connector from the Battery 2300 mAh.
Do not damage the components on the PBA Complete
Assy!
3.3 Clip USB
Remove the two Screw 3.0 screws holding the Clip USB by
using a screwdriver with Bits (JCIS No 0).
Scrap! Not to be reused!
Remove the Clip USB.

Working Instruction (mech)
1271-7733 Rev 2

Sony Mobile Communications AB – Company Internal
10(76)
Disassembly
3.4 Carrier Spbox
Remove the BtB connectors from the Camera 13MP and the
FPC AVP with the Front Opening Tool.
Do not damage the components on the PBA Complete!
Remove the two Screw 3.0 screws holding the Carrier
Spbox Assy by using a screwdriver with Bits (JCIS No 0).
Scrap! Not to be reused!
Also remove the Screw 3.5 screw holding the Carrier Spbox
Assy, by using a screwdriver with Bits (JCIS No 0).
Scrap! Not to be reused!
Gently lift up the Carrier Spbox Assy.

Working Instruction (mech)
1271-7733 Rev 2

Sony Mobile Communications AB – Company Internal
11(76)
Disassembly
3.5 PBA Complete Assy
Use the Front Opening Tool to remove the BtB connector
from Front Assy Unit connected to the PBA Complete Assy.
Do not damage the components on the PBA Complete!
Gently lift the part of the Ant NFC that is above the BtB
connector from FPC Side Key and peal of the Adhesive NFC
from the BtB with a Flex Film Assembly Tool.
Do not damage the Ant NFC!
Use the Front Opening Tool to remove the BtB connector
from the FPC Side Key.
Do not damage the components on the PBA Complete!
Also remove the BtB connector from the Camera 2.2 MP
and the FPC camera Key PBA from the PBA Complete with
a Front Opening Tool.
Do not damage the components on the PBA Complete!
Use the Front Opening Tool to remove the BtB connector
from the PBA Complete and loosen the wire from the
Adhesive Vibrator.
Do not damage the components on the PBA Complete!

Working Instruction (mech)
1271-7733 Rev 2

Sony Mobile Communications AB – Company Internal
12(76)
Disassembly
Remove the Screw 3.0 holding the PBA Complete Assy by
using a screwdriver with Bits (JCIS No 0).
Scrap! Not to be reused!
Gently lift the PBA Complete Assy, Front left side first as
shown in picture.
Do not damage the Flex Films or the wires!

Working Instruction (mech)
1271-7733 Rev 2

Sony Mobile Communications AB – Company Internal
13(76)
Disassembly
3.6 Ant NFC
Gently peel off and lift the Ant NFC starting from the
opposite side of the connector.
Open the ZIF connector with the Front Opening Tool and
loosen the Ant NFC from the PBA Complete.
Do not damage the components on the PBA Complete!

Working Instruction (mech)
1271-7733 Rev 2

Sony Mobile Communications AB – Company Internal
14(76)
4 Replacement
4.1 Back Cover Assy
Follow the 3.1 Disassembly instructions!
Prepare a new Back Cover Assy.
Follow the 5.6 Reassembly instructions!
4.2 Clip USB
Follow the 3.1 – 3.3 Disassembly instructions!
Prepare a new Clip USB.
Follow the 5.4 – 5.6 Reassembly instructions!
4.3 Carrier Spbox Assy
Follow the 3.1 – 3.4 Disassembly instructions!
Prepare a new Carrier Spbox Assy.
Follow the 5.3 – 5.6 Reassembly instructions!

Working Instruction (mech)
1271-7733 Rev 2

Sony Mobile Communications AB – Company Internal
15(76)
Replacement
4.4 PBA Complete Assy
Follow the 3.1 – 3.5 Disassembly instructions!
Prepare a new PBA Complete Assy.
Follow the 5.2 – 5.6 Reassembly instructions!
4.5 Front Assy Unit
Follow the 3.1 – 3.5 Disassembly instructions!
Prepare a new Front Assy Unit.
Follow the 5.2 – 5.6 Reassembly instructions!

Working Instruction (mech)
1271-7733 Rev 2

Sony Mobile Communications AB – Company Internal
16(76)
Replacement
4.6 Adhesive Backcover
Follow the 3.1 Disassembly instructions!
Prepare a new Adhesive Backcover.
Carry out the Installation as described below!
Follow the 5.6 Reassembly instructions!
INSTALLATION
Place the new Backcover Adhesive in the Backcover
Adhesive alignment fixture.
Place the Back Cover on top of the Backcover in the
Backcover Adhesive alignment fixture.
Secure its position by applying some pressure with your hand
during 5s on the Back Cover
REMOVAL
Make sure that both the Back Cover Assy and the Front
Assy Unit is clean from old Adhesive Battery.

Working Instruction (mech)
1271-7733 Rev 2

Sony Mobile Communications AB – Company Internal
17(76)
Replacement
4.7 Adhesive Battery
Follow the 3.1 – 3.5 Disassembly instructions!
Follow the 4.50, 4.9, 4.15 and 4.14 Removal instructions!
Carry out the Removal as described below!
Prepare a new Adhesive Battery.
Carry out the Installation as described below!
Follow the 4.14, 4.15, 4.9 and 4.50 Installation instructions!
Follow the 5.2 –5.6 Reassembly instructions!
Scrap the Adhesive Battery, not to be reused!
REMOVAL
Peel of the old Adhesive Battery and its residue with your
fingers.
INSTALLATION
Place the Adhesive Battery with the protection film at its place
on the Battery 2300 mAh and apply some pressure with your
fingers before removing the protection film.

Working Instruction (mech)
1271-7733 Rev 2

Sony Mobile Communications AB – Company Internal
18(76)
Replacement
4.8 Adhesive Label
Carry out the Removal as described below!
Prepare a new Adhesive Label.
Carry out the Installation as described below!
REMOVAL
Open the Cover Card.
SIM card and Memory Card needs to be removed!
Open the Cover Card and unfold the Label Mobile Phone.
Gently peel off the Adhesive Label.
Scrap the Adhesive Label! Not to be reused!
INSTALLATION
Attach a new Adhesive Label to the Label Mobile Phone
according to the picture.

Working Instruction (mech)
1271-7733 Rev 2

Sony Mobile Communications AB – Company Internal
19(76)
Replacement
4.9 Adhesive Vibrator
Follow the 3.1 – 3.2 Disassembly instructions!
Follow the 4.50 Removal instructions!
Carry out the Removal as described below!
Prepare a new Adhesive Vibrator.
Carry out the Installation as described below!
Follow the 4.50 Installation instructions!
Follow the 5.5– 5.6 Reassembly instructions!
REMOVAL
Use the Flex Film Assembly Tool to peel of the Adhesive
Vibrator.
INSTALLATION
Place the new Adhesive Vibrator in the cavity for the vibrator.

Working Instruction (mech)
1271-7733 Rev 2

Sony Mobile Communications AB – Company Internal
20(76)
Replacement
4.10 Adhesive Vibrator Wire
Follow the 3.1 – 3.2 Disassembly instructions!
Carry out the Removal as described below!
Prepare a new Adhesive Vibrator Wire.
Carry out the Installation as described below!
Follow the 5.5 – 5.6 Reassembly instructions!
REMOVAL
Use the Front Opening Tool to remove the BtB connector
from the Vibrator and remove the wire from the Vibrator
Adhesive.
Do not damage the components on the PBA Complete!
Gently peel of the Adhesive Vibrator Wire.
INSTALLATION
Place the new Adhesive Vibrator Wire on the PBA Complete
according to marking in PBA Complete.
Connect the BtB Connector from the Vibrator to the PBA
Complete and secure its wires on the Adhesive Vibrator Wire
with your fingers.