MEX-DV1100, MEX-DV2100 - Sony Car Audio Service Manual (repair manual)

2008J05-1

© 

2008.10

Model Name Using Similar Mechanism

MEX-DV1000

Mechanism Type

MG-612Z-187

Optical Pick-up Name

KHS-360A

Photo: MEX-DV2100

Manufactured under license 
under U.S. Patent #'s: 
5,451,942; 5,956,674; 

5,974,380; 5,978,762; 6,487,535 & other U.S. 
and worldwide patents issued & pending. DTS 
and DTS Digital Surround are registered 
trademarks and the DTS logos and Symbol are 
trademarks of DTS, Inc. © 1996-2007 DTS, Inc. 
All Rights Reserved.

“DVD VIDEO,” “DVD-R,” “DVD-RW,” 
“DVD+R,” and “DVD+RW” are trademarks.

“DivX” and “DivX Certified” are 
registered trademarks or trademarks 
of DivX, Inc.

THIS PRODUCT IS LICENSED UNDER THE 
MPEG-4 VISUAL PATENT PORTFOLIO 
LICENSE FOR THE PERSONAL AND NON-
COMMERCIAL USE OF A CONSUMER FOR 
DECODING MPEG-4 VIDEO THAT WAS 
ENCODED BY A CONSUMER ENGAGED IN 
A PERSONAL AND NON-COMMERCIAL 
ACTIVITY AND/OR WAS OBTAINED FROM 
A VIDEO PROVIDER LICENSED BY MPEG 
LA TO PROVIDE MPEG-4 VIDEO. NO 
LICENSE IS GRANTED OR SHALL BE 
IMPLIED FOR ANY OTHER USE. 
ADDITIONAL INFORMATION INCLUDING 
THAT RELATING TO PROMOTIONAL, 
INTERNAL AND COMMERCIAL USES AND 
LICENSING MAY BE OBTAINED FROM 
MPEG LA, LLC. SEE 
HTTP://WWW.MPEGLA.COM

Manufactured under license 
from Dolby Laboratories.
“Dolby,” “Pro Logic,” and the 

double-D symbol are trademarks of Dolby 
Laboratories.

Microsoft, Windows Media, 
and the Windows logo are 
trademarks or registered 
trademarks of Microsoft 

Corporation in the United States and/or other 
countries.

Laser: Semiconductor laser
Signal format system: PAL (Russian model)

PAL/NTSC switchable
(E and Indian models)

Signal-to-noise ratio: 120 dB
Frequency response: 10 – 20,000 Hz
Wow and flutter: Below measurable limit
Harmonic distortion: 0.01 %

Tuning range: 87.5 – 108.0 MHz
Antenna (aerial) terminal:

E x ternal antenna (aerial) connector

Intermediate frequency: 10.7 MHz/450 kHz
Usable sensitivity: 9 dBf
Selectivity: 75 dB at 400 kHz
Signal-to-noise ratio: 67 dB (stereo), 69 dB (mono)
Harmonic distortion at 1 kHz: 0.5 % (stereo),

0.3 % (mono)

Separation: 35 dB at 1 kHz
Frequency response: 30 – 15,000 Hz

Tuning range: 531 – 1,602 kHz
Antenna (aerial) terminal:

External antenna (aerial) connector

Intermediate frequency: 10.7 MHz/450 kHz
Sensitivity: 30 μV

Outputs: Speaker outputs (sure seal connectors)
Speaker impedance: 4 – 8 ohms
Maximum power output: 52 W 

× 4 (at 4 ohms)

MW: 531 – 1,602 kHz
LW: 153 – 279 kHz

External antenna (aerial) connector

Intermediate frequency: 10.7 MHz/450 kHz
Sensitivity: MW: 30 μV, LW: 40 μV

Video output terminals (front/rear) (DV2100)
Video output terminals(DV1100)
Audio output terminals (front/rear) (DV2100)
Rear audio output (DV1100)
Center output terminal (DV2100)
Subwoofer output terminal (DV2100)
Power antenna (aerial) relay control terminal
Power amplifier control terminal

Telephone ATT control terminal (DV2100)
Illumination control terminal (DV2100)
BUS audio input/AUX audio input terminals
BUS control input terminal
Remote controller input terminal
Antenna (aerial) input terminal
Parking break control terminal
Microphone input terminal
AUX input jack (stereo mini jack)

– Continued on next page –

Notes on chip component replacement
• 

Never reuse a disconnected chip component.

• 

Notice that the minus side of a tantalum capacitor may be dam-
aged by heat.

Flexible Circuit Board Repairing
• 

Keep the temperature of soldering iron around 270 °C during 
repairing.

• 

Do not touch the soldering iron on the same conductor of the 
circuit board (within 3 times).

• 

Be careful not to apply force on the conductor when soldering 
or unsoldering.

COMPONENTS  IDENTIFIED  BY  MARK 0 OR  DOTTED  LINE  
WITH  MARK 0 ON  THE  SCHEMATIC  DIAGRAMS  AND  IN  
THE  PARTS  LIST  ARE  CRITICAL  TO  SAFE  OPERATION.
REPLACE  THESE  COMPONENTS  WITH  SONY  PARTS 

CAUTION
Use of controls or adjustments or performance of procedures other than 
those specifi ed herein may result in hazardous radiation exposure.

This label is located on the bottom of the
chassis.

-

This label is located on the drive unit’s internal
chassis.

This label is located on the drive unit’s internal
chassis.

Your dealer may not handle some of the above listed 
accessories. Please ask the dealer for detailed 
information.

DivX, DivX Certified, and associated logos are 
trademarks of DivX, Inc. and are used under license.

US and foreign patents licensed from Dolby 
Laboratories.

MPEG Layer-3 audio coding technology and 
patents licensed from Fraunhofer IIS and Thomson.

This product is protected by certain intellectual 
property rights of Microsoft Corporation. Use or 
distribution of such technology outside of this 
product is prohibited without a license from 
Microsoft or an authorized Microsoft subsidiary.

Card remote commander:
RM-X162 (DV2100: Russian model)
RM-X163 (DV2100: E and Indian models)
RM-X166 (DV1100: Russian model)
RM-X167 (DV1100: E and Indian models)
Parts for installation and connections (1 set)

Power requirements: 12 V DC car battery 

(negative ground (earth))

Dimensions: Approx. 178 

× 50 × 181 mm 

(7 /

8

× 2 × 7  /

4

 in) (w/h/d)

1

1

Mounting dimensions: Approx. 182 

× 53 × 181 mm 

(7  /

4

× 2  /

8

× 7  /

4

 in) (w/h/d)

1

1

1

Mass: Approx. 1.4 kg (3 lb 2 oz)

  .............................................   4

  ..................................................................   8

3-1.   Disassembly Flow  ..........................................................   13
3-2.   SUB Panel Complete Assy .............................................   13
3-3.   DVD Mechanism Deck Block ........................................   14
3-4.   MAIN Board, DC Fan (25X25) (M901)  ........................   14
3-5.   Chassis (T612Z) SUB Assy, SENSOR Board ................   15
3-6.   Chassis (OP, Z) Complete Assy ......................................   15
3-7.   SERVO Board  ................................................................   16

ADJUSTMENTS 

 ........................   17

5-1.  Block Diagram - SERVO/VIDEO Section - ...................   18
5-2.  Block Diagram - TUNER/AUDIO Section - ..................   19
5-3. Block 

Diagram 

 

- PANEL/POWER SUPPLY Section - ............................   20

5-4.  Printed Wiring Board - SERVO Section (1/2) - ..............   22
5-5.  Printed Wiring Boards - SERVO Section (2/2) - ............   23
5-6.  Schematic Diagram - SERVO Section (1/4) - .................   24
5-7.  Schematic Diagram - SERVO Section (2/4) - .................   25
5-8.  Schematic Diagram - SERVO Section (3/4) - .................   26
5-9.  Schematic Diagram - SERVO Section (4/4) - .................   27
5-10.  Printed Wiring Board - MAIN Section (1/2) - ................   28
5-11.  Printed Wiring Boards - MAIN Section (2/2) - ..............   29
5-12.  Schematic Diagram - MAIN Section (1/6) - ...................   30
5-13.  Schematic Diagram - MAIN Section (2/6) - ...................   31
5-14.  Schematic Diagram - MAIN Section (3/6) - ...................   32
5-15.  Schematic Diagram - MAIN Section (4/6) - ...................   33
5-16.  Schematic Diagram - MAIN Section (5/6) - ...................   34
5-17.  Schematic Diagram - MAIN Section (6/6) - ...................   35
5-18.  Printed Wiring Board - SUB Board - ..............................   36
5-19.  Schematic Diagram - SUB Board - .................................   37
5-20.  Printed Wiring Board - KEY Board -..............................   38
5-21.  Schematic Diagram - KEY Board - ................................   39

6-1. Main 

Section 

...................................................................  52

6-2.  Front Panel Section .........................................................   53
6-3.  DVD Mechanism Deck Section (MG-612Z-187) ..........   54

  ..............................   55

The laser diode in the optical pick-up block may suffer electrostat-
ic break-down because of the potential difference generated by the 
charged electrostatic load, etc. on clothing and the human body.
During repair, pay attention to electrostatic break-down and also 
use the procedure in the printed matter which is included in the 
repair parts.
The fl exible board is easily damaged and should be handled with 
care.

NOTE  ON  LASER  DIODE  EMISSION  CHECK
The laser beam on this model is concentrated so as to be focused 
on the disc refl ective surface by the objective lens in tha optical 
pick-up block. Therefore, when checking the laser diode emission, 
observe from more than 30 cm away from the objective lens.

UNLEADED  SOLDER
Boards requiring use of unleaded solder are printed with the lead-
free mark (LF) indicating the solder contains no lead.
(Caution: Some printed circuit boards may not come printed with 

the lead free mark due to their particular size)

Unleaded solder has the following characteristics.
•  Unleaded solder melts at a temperature about 40 °C higher 

than ordinary solder.

 

Ordinary soldering irons can be used but the iron tip has to be 
applied to the solder joint for a slightly longer time.

 

Soldering irons using a temperature regulator should be set to 
about 350 °C.
Caution:  The printed pattern (copper foil) may peel away if the 

heated tip is applied for too long, so be careful!

• Strong 

viscosity

 

Unleaded solder is more viscous (sticky, less prone to fl ow) 
than ordinary solder so use caution not to let solder bridges 
occur such as on IC pins, etc.

•  Usable with ordinary solder
 

It is best to use only unleaded solder but unleaded solder may 
also be added to ordinary solder.

Label indication

 Signal format  Region 

Part No.

 Destination

system code 

 PAL 

3 

3-276-503-0[]  DV1100: E model

 PAL 

5 

3-276-504-0[]  DV1100: Indian model

 PAL 

5 

3-276-506-0[]  DV1100: Russian model

 PAL 

3 

3-276-509-0[]  DV2100: E model

 PAL 

5 

3-276-510-0[]  DV2100: Indian model

 PAL 

5 

3-276-512-0[]  DV2100: Russian model

ABOUT  THE  SERVO  BOARD  E,  F  SIGNAL  OFFSET  
ADJUSTMENT  CIRCUIT  DELETION
In this set, E, F SIGNAL OFFSET ADJUSTMENT circuit on the 
SERVO board is deleted in the midway of production.
The SERVO board from which the E, F SIGNAL OFFSET AD-
JUSTMENT circuit has been deleted should not execute the E, F 
SIGNAL OFFSET ADJUSTMENT. 

Parts concerning this change are expressed as follows.

TYPE A: There is E, F SIGNAL OFFSET ADJUSTMENT CIR-

CUIT

TYPE B: There is no E, F SIGNAL OFFSET ADJUSTMENT 

CIRCUIT

•  The set since the following serial No. is the set from which the 

circuit is deleted.

MEX-DV1100

E (PAL)

since 1501902

Russian

since 1509667

Indian

since 1505187

Indian (Muruti Suzuki)

ALL

MEX-DV2100

E (PAL)

since 1502223

Russian

since 1502291

Indian

since 1501723

NOTE  THE  IC501  ON  THE  MAIN  BOARD  REPLACING  
(MEX-DV2100  ONLY)
When the IC501 on the MAIN board of MEX-DV2100 is replaced, 
it is necessary to update it.
Confi rm the update method to each service headquarters.