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Follow the procedures in Before You Begin. 2. Remove the computer cover (see Removing the Computer Cover). 3. Disconnect the processor fan and heat sink assembly cable from the processor fan connector on the system board (see System Board Components). 4. Carefully move away any cables that are routed over the processor fan and heat sink assembly. 5. Remove the processor fan and heat sink assembly. Inspiron™ 535/537/545 a. Loosen the four captive screws securing the processor fan and heat sink assembly and lift it straight up. Inspiron 546 a. Rotate the clamp lever 180 degrees counter-clockwise to release the clamp grip from the bracket projection. WARNING: Before working inside your computer, read the safety information that shipped with your computer. For additional safety best practices information, see the Regulatory Compliance Homepage at WARNING: To guard against likelihood of electric shock, laceration by moving fan blades or other unexpected injuries, always unplug your computer from the electrical outlet before removing the cover. WARNING: Do not operate your equipment with any cover(s) (including computer covers, bezels, filler brackets, front-panel inserts, etc.) removed. CAUTION: The processor fan with the heat sink is one single unit. Do not try to remove the fan separately. CAUTION: Do not touch the fan blades when you are removing the processor fan and heat sink assembly. This could damage the fan. CAUTION: Despite having a plastic shield, the heat sink fan assembly may be very hot during normal operation. Be sure that it has had sufficient time to cool before you touch it. 1 processor fan and heat sink assembly NOTE: The processor fan and heat sink assembly in your computer may not look exactly like the one shown in the illustration above. b. Rotate the processor fan and heat sink assembly upward gently, and remove it from the computer. Lay the processor fan and heat sink assembly down on its top, with the thermal grease facing upward. Replacing the Processor Fan and Heat Sink Assembly 1. Clean the thermal grease from the bottom of the processor fan and heat sink assembly. 2. Apply the new thermal grease to the top of the processor. 3. Replace the processor fan and heat sink assembly. Inspiron 535/537/545 a. Align the captive screws on the processor fan and heat sink assembly to the four metal screw hole projections on the system board. b. Tighten the four captive screws that secure the processor fan and heat sink assembly to the system board. Inspiron 546 a. Place the processor fan and heat sink assembly back onto the bracket. b. Ensure that the two clamp grips are aligned with the two bracket projections. c. Hold the processor fan and heat sink fan assembly in place and rotate the clamp lever 180 degrees clockwise to secure the processor fan and heat sink assembly. 1 bracket 2 clamp grip 3 bracket projection 4 clamp lever 5 processor fan and heat sink assembly NOTE: The processor fan and heat sink assembly in your computer may not look exactly like the one shown in the illustration above. CAUTION: When reinstalling the fan, ensure that you do not pinch the wires that run between the system board and the fan. CAUTION: Ensure that you apply new thermal grease. New thermal grease is critical for ensuring adequate thermal bonding, which is a requirement for optimal processor operation. NOTE: Ensure that the processor fan and heat sink assembly is correctly seated and secure. 4. Connect the processor fan and heat sink assembly cable to the fan connector on the system board (see System Board Components). 5. Replace the computer cover (see Replacing the Computer Cover). 6. Connect your computer and devices to an electrical outlet, and turn them on. Removing the Chassis Fan 1. Follow the procedures in Before You Begin. 2. Remove the computer cover (see Removing the Computer Cover). 3. Disconnect the chassis fan cable from the chassis fan connector on the system board (see System Board Components). 4. Remove the screws securing the chassis fan. 5. Slide the chassis fan towards the front of the computer and lift it up. Inspiron™ 535/537 Inspiron 545/546 1 processor fan and heat sink assembly 2 clamp lever 3 bracket projection 4 clamp grip 5 bracket CAUTION: Do not touch the fan blades when you are removing the chassis fan. This could damage the fan. 1 screws (2) 2 chassis fan Replacing the Chassis Fan 1. Follow the procedures in Before You Begin. 2. Slide the chassis fan in place towards the back of the computer. 3. Replace the screws that secure the chassis fan. 4. Connect the chassis fan cable to the chassis fan connector on the system board (see System Board Components). 5. Replace the computer cover (see Replacing the Computer Cover). 6. Connect your computer and devices to an electrical outlet, and turn them on. Back to Contents Page 1 screws (4) 2 chassis fan Back to Contents Page Front I/O Panel Dell™ Inspiron™ 535/537/545/546 Service Manual Removing the Fro...