Sony Xperia ZR User manual

1273-7033 Rev 1

Sony Mobile Communications AB – Company Internal
Working Instructions
- mechanical -
Xperia
TM
ZR
C5502, C5503 & M36h

Working Instruction (mech)
1273-7033 Rev 1

Sony Mobile Communications AB – Company Internal
2(71)
CONTENTS
1Exterior Views................................................................................. 5
2Tools ................................................................................................ 6
3Disassembly.................................................................................... 7
3.1 Cover Battery........................................................................................ 8
3.2 Battery 2300 mAh BA950..................................................................... 8
3.3 Sheet FPC Relay................................................................................... 9
3.4 Display ................................................................................................ 10
3.5 Support Plate...................................................................................... 11
3.6 Camera................................................................................................ 13
3.7 Main PBA ............................................................................................ 14
3.8 RF Coax Cable.................................................................................... 16
3.9 Lightguide........................................................................................... 16
3.10 Lightguide Sheet ................................................................................ 16
3.11 Sheet Battery Side ............................................................................. 17
3.12 Holder Side Keys................................................................................ 17
3.13 FPC Relay Assy.................................................................................. 18
4Replacement ................................................................................. 19
4.1 Cover Battery...................................................................................... 19
4.2 Battery 2300 mAh BA950................................................................... 19
4.3 Sheet FPC Relay................................................................................. 19
4.4 Display ................................................................................................ 19
4.5 Support Plate...................................................................................... 20
4.6 Camera................................................................................................ 20
4.7 Main PBA ............................................................................................ 20
4.8 RF Coax Cable.................................................................................... 21
4.9 Lightguide........................................................................................... 22
4.10 Lightguide Sheet ................................................................................ 22
4.11 Sheet Battery Side ............................................................................. 22
4.12 Holder Side Keys................................................................................ 22
4.13 FPC Relay ........................................................................................... 23
4.14 Cover Main.......................................................................................... 25
4.15 Adhesive Display ............................................................................... 25
4.16 Card Connector Tray.......................................................................... 26
4.17 Cushion 2nd MIC ................................................................................. 27
4.18 Cushion 3 x 3 mm .............................................................................. 28
4.19 Cushion 3 x 8 mm .............................................................................. 29
4.20 Cushion MIC ....................................................................................... 30

Working Instruction (mech)
1273-7033 Rev 1

Sony Mobile Communications AB – Company Internal
3(71)
4.21 Cushion Window ................................................................................ 31
4.22 FPC PBA NFC ..................................................................................... 32
4.23 FPC Top Compl .................................................................................. 33
4.24 Gasket 2nd MIC.................................................................................... 35
4.25 Gasket Chat Camera .......................................................................... 36
4.26 Gasket Key ......................................................................................... 37
4.27 Gasket Key Cam................................................................................. 38
4.28 Key Camera ........................................................................................ 39
4.29 Key Power........................................................................................... 40
4.30 Key Volume ........................................................................................ 41
4.31 Label Mobile Phone............................................................................ 42
4.32 Loudspeaker & Adhesive Speaker.................................................... 43
4.33 Net Speaker ........................................................................................ 44
4.34 Nut....................................................................................................... 45
4.35 Panel Key Power & Adhesive Panel Key Power .............................. 46
4.36 Panel Side L........................................................................................ 47
4.37 Panel Side R Bottom .......................................................................... 48
4.38 Panel Side R Top................................................................................ 49
4.39 PBA Antenna & Adhesive PBA Antenna .......................................... 50
4.40 Sheet Magnetic NFC........................................................................... 52
4.41 Water Indicator ................................................................................... 53
4.42 Washer Key Power............................................................................. 56
4.43 Board Swap - Replacement ............................................................... 57
4.44 Board Swap – Change Label ............................................................. 58
4.45 Board Swap – Customize of Software .............................................. 59
5Re-Assembly................................................................................. 60
5.1 FPC Relay Assy.................................................................................. 61
5.2 Holder Side Keys................................................................................ 62
5.3 Sheet Battery Side ............................................................................. 63
5.4 Lightguide Sheet ................................................................................ 63
5.5 Lightguide........................................................................................... 63
5.6 RF Coax Cable.................................................................................... 64
5.7 Main PBA ............................................................................................ 65
5.8 Camera................................................................................................ 67
5.9 Support Plate...................................................................................... 68
5.10 Display ................................................................................................ 69
5.11 Sheet FPC Relay................................................................................. 70
5.12 Battery 2300 mAh BA950................................................................... 70
5.13 Cover Battery...................................................................................... 70
6Revision History ........................................................................... 71

Working Instruction (mech)
1273-7033 Rev 1

Sony Mobile Communications AB – Company Internal
4(71)
For general information about mechanical repair related issues, refer to
1220-1333: Generic Repair Manual - mechanical

Working Instruction (mech)
1273-7033 Rev 1

Sony Mobile Communications AB – Company Internal
5(71)
1 Exterior Views

Working Instruction (mech)
1273-7033 Rev 1

Sony Mobile Communications AB – Company Internal
6(71)
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. Dentist hook
7. Battery Removal Tool
8. Generic Press Clamp 45N
9. Display Adhesive alignment fixture
10. Display Press Top Inlay
11. Bottom Press Inlay
12. Side Panel press
13. Side Panel Press Pad
14. Nylon pointer
For part not on the tools above, refer to the ‘Tools Catalogue/Matrix’!

Working Instruction (mech)
1273-7033 Rev 1

Sony Mobile Communications AB – Company Internal
7(71)
3 Disassembly
The Disassembly is done to the following modules:
1. Cover Battery
2. Battery 2300 mAh BA950
3. Sheet FPC Relay
4. Display
5. Support Plate
6. Camera
7. Main PBA
8. RF Coax Cable
9. Lightguide
10. Lightguide Sheet
11. Sheet Battery Side
12. Holder Side Keys
13. FPC Relay Assy*
14. Cover Main Assy*
*) Assy and Unit is used when several parts are handled
2
5
7
1
4
3
6
12
8
9
10
11
13
14

Working Instruction (mech)
1273-7033 Rev 1

Sony Mobile Communications AB – Company Internal
8(71)
Disassembly
3.1 Cover Battery
Open the Cover Battery, bottom side first.
3.2 Battery 2300 mAh BA950
Remove Battery, bottom side first.

Working Instruction (mech)
1273-7033 Rev 1

Sony Mobile Communications AB – Company Internal
9(71)
Disassembly
3.3 Sheet FPC Relay
Use a Flex Film Assembly Tool to grab the Sheet FPC Relay
in the upper left corner.
Do not damage the FPC beneath!
Gently peel of the Sheet FPC Relay!
Scrap! Not to be reused!

Working Instruction (mech)
1273-7033 Rev 1

Sony Mobile Communications AB – Company Internal
10(71)
Disassembly
3.4 Display
Use the “Disassembly Machine” (1276-0592) and follow the
associated instruction.
The Disassembly Machine must be used when removing
the Display!

Working Instruction (mech)
1273-7033 Rev 1

Sony Mobile Communications AB – Company Internal
11(71)
Disassembly
3.5 Support Plate
Remove the 6 screws holding the Support Plate by using a
screwdriver with Bits (JCIS No 0).
Scrap! Not to be reused!
Push the Support Plate from the battery side to make a gap
between the Support Plate and the Cover Main Assy.
Insert a Guitar Pick just below the On/Off button (between
the areas marked in red on the picture below).
Do not damage the Cover Main!
Loosen the adhesive marked on the picture by sliding the
Guitar Pick to each side.
Do not damage the Cover Main!
Loosen the adhesive marked on the picture by inserting the
Battery Removal Tool.
Do not damage the Cover Main!
When the all the adhesive is loosened, lift the long side of
the Support Plate to make it free from the Cover Main.

Working Instruction (mech)
1273-7033 Rev 1

Sony Mobile Communications AB – Company Internal
12(71)
Disassembly: Support Plate
Move the Support Plate in the arrows direction to free it from
the Cover Main.

Working Instruction (mech)
1273-7033 Rev 1

Sony Mobile Communications AB – Company Internal
13(71)
Disassembly
3.6 Camera
Open the ZIF connector with the Front Opening Tool.
Use a Flex Film Assembly Tool to remove the Camera by
lifting it out from its cavity.
Do not damage the Camera!

Working Instruction (mech)
1273-7033 Rev 1

Sony Mobile Communications AB – Company Internal
14(71)
Disassembly
3.7 Main PBA
Gently loosen the BtB from the FPC BPA NTC with a Front
Opening Tool.
Do not damage the components on the Main PBA!
Gently loosen the BtB from the FPC Relay with a Front
Opening Tool.
Do not damage the components on the Main PBA!
Gently loosen the BtB from the FPC Top Compl. with a Front
Opening Tool.
Do not damage the components on the Main PBA!
Gently loosen the connector on the RF Coax Cable from the
Main PBA with your fingers.
Use a Dentist Hook to loosen the Man PBA from its cavity.

Working Instruction (mech)
1273-7033 Rev 1

Sony Mobile Communications AB – Company Internal
15(71)
Disassembly: Main PBA
Use the pre-made chamfer on the Main PBA!
Do not damage the Main PBA!
Lift the Main PBA to free it from the FPC’s before removing it
by moving the Main PBA in the arrows direction.
Do not damage the FPC’s!

Working Instruction (mech)
1273-7033 Rev 1

Sony Mobile Communications AB – Company Internal
16(71)
Disassembly
3.8 RF Coax Cable
Gently loosen the connector on the RF Coax Cable from the
PBA Antenna with your fingers.
Lift the RF Coax Cable from the Cover Main.
3.9 Lightguide
Gently lift the Lightguide from its cavity with your fingers.
3.10 Lightguide Sheet
Gently lift the Lightguide Sheet from its cavity with a Flex
Film Assembly Tool.
Scrap, not to be reused!

Working Instruction (mech)
1273-7033 Rev 1

Sony Mobile Communications AB – Company Internal
17(71)
Disassembly
3.11 Sheet Battery Side
Use a Dentist Hook to remove the Sheet Battery Side.
Scrap, not to be reused!
3.12 Holder Side Keys
Remove the Holder Side Keys with your fingers.
Scrap, not to be reused!

Working Instruction (mech)
1273-7033 Rev 1

Sony Mobile Communications AB – Company Internal
18(71)
Disassembly
3.13 FPC Relay Assy
Use a Flex Film Assembly Tool to loosen adhesive on the
FPC from the Cover Main on the 3 places marked on the
picture.
Use a Flex Film Assembly Tool to completely loosen the
FPC Relay Assy from the Cover Main.
Scrap, not to be reused!
Be careful not to damage the FPC or the components
on the FPC underneath.

Working Instruction (mech)
1273-7033 Rev 1

Sony Mobile Communications AB – Company Internal
19(71)
4 Replacement
4.1 Cover Battery
Follow the 3.1 Disassembly instructions!
Prepare a new Cover Battery.
Follow the 5.13 Reassembly instructions!
4.2 Battery 2300 mAh BA950
Follow the 3.1 – 3.2 Disassembly instructions!
Prepare a new Battery 2300 mAh BA950.
Follow the 5.12 – 5.13 Reassembly instructions!
4.3 Sheet FPC Relay
Follow the 3.1 – 3.3 and Disassembly instructions!
Scrap Sheet FPC Relay, not to be reused!
Prepare a new Sheet FPC Relay.
Follow the 5.11 – 5.13 Reassembly instructions!
4.4 Display
Follow the 3.1 – 3.4 Disassembly instructions!
Prepare a new Display.
Follow the 5.10 – 5.13 Reassembly instructions!

Working Instruction (mech)
1273-7033 Rev 1

Sony Mobile Communications AB – Company Internal
20(71)
Replacement
4.5 Support Plate
Follow the 3.1 – 3.5 Disassembly instructions!
Scrap Support Plate, not to be reused!
Prepare a new Support Plate.
Follow the 5.9 – 5.13 Reassembly instructions!
4.6 Camera
Follow the 3.1 – 3.6 Disassembly instructions!
Prepare a new Camera.
Carry out the Installation as described below!
Follow the 5.8 – 5.13 Reassembly instructions!
4.7 Main PBA
Follow the 3.1 – 3.7 Disassembly instructions!
Follow the 4.25 Removal instructions!
Prepare a new Main PBA.
Follow the 4.25 Reassembly instructions!
Follow the 5.7 –5.13 Reassembly instructions!