Tip & How-To about Televison & Video

How to replace a DLP light engine.

To replace the light engine on a DLP or LCD television you need to remove the power first. Safety should be the most important step. Never work on the TV while powered.

Next you will need to remove the lower back cover to access the light engine. This requires removing all the screws around the perimeter of the panel and with some sets you may need to remove a few screws located on the input/output panel. Generally the screws will be marked with an arrow pointing to the one's which need to be removed.

The light engine is the large assembly in the middle of the set with the lamp shining through it and the lense, exiting vertically to the mirror. It will slide to the rear once all the mounting screws are removed along with any connecting cables.

To remove the light engine take out all the screws holding the light engine assembly in. They should be around the perimeter and generally are marked with arrows. On some sets there could be a few screws located at various locations on the board, but this is rare and should become obvious. Just don't force the board. If it will not move you need to look for more hold down screws. Sometimes they can be hidden very well, but generally it is not that difficult.

Before disconnecting any cables mark them for easy reassembly. This can be done by using wire numbers, a label maker or my favorite, a sharpie. Mark all connectors on both ends and make each mark unique. The best approach is to number them consecutively beginning with 1.

Once you are confident that all the cables are adequately marked for reassembly remove all cables necessary to get the engine out. The lamp may need to be removed also. If you have already changed the lamp you should be familiar with the process. If you have not done this before I have a tip at http://www.fixya.com/support/r4168009-change_lamp_in_dlp_projection_tv which explains the process.Always be careful when handling the lamp. Never touch the lamp with your bare hands. The oil from your hands will burn a hole in the lamp when you turn it on.

With the screws removed from the light engine, and the wires all disconnected, you should be able to slide the light engine to the rear and remove it from the chassis. The new light engine should come with installation instructions. You may also need to change some of the wires or other parts from the old light engine. This will all be noted in the installation instructions with the new light engine.

While you have the light engine out this would be a good time to clean the mirror, the rear of the screen and the new lense on the replacement engine. Use a lint free cloth, diapers work very well for this, and window cleaner (no ammonia). Never spray the engine or other surfaces. Spray the cloth and using a circular motion clean the lense, mirror, screen, etc. Be careful cleaning the mirror if it is mylar (thick aluminum foil) as too much pressure will tear it.

Once the engine is out and removed from the board, install the new unit and reinstall the board. All parts necessary should be with the new unit , as well as installation instructions, but if not remove what you need from the old engine and install on the new unit.

Slide the new light engine into the chassis and replace all cables being careful to make sure they are in the proper sockets. If you labeled all the connectors correctly this should be easy.

Install any remaining components and test the unit. The back panel must be on for this. There is an interlock for the lamp assembly which will stop the unit from turning on. Be certain that this is hooked up and orientated correctly. If the unit will not start see my tip at http://www.fixya.com/support/r5207658-dlp_tv_run_after_replacing_lamp which should help solve this problem.

Some units may require a lamp or engine reset but this is rare and different for each unit. For more help and locations of components go to http://www.retrevo.com where you may be able to download you unit's operation and sometimes the service manual for free. This will be helpful for any setup instructions and location of parts.

If all went well your unit should be working OK at this point. Parts can be obtained at www.encompass.com or www.shopjimmy.com . Either site has good prices for parts but this part will be expensive.

Thanks for using FixYa and for the great rating.

hardrocko

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