LASERJET 1160 FUSER ASSEMBLY

The fuser assembly unit (fuser unit) installed in your HP LaserJet 1160 Printer is an important consumable component. The technical condition of this consumable component is directly defining the overall print quality results achieved by your laser printer. The lifespan of the installed fuser unit depends mainly upon the chosen fusing mode (higher fusing temperatures = shorter lifespan).
You must replace the installed fuser unit, if the print quality is gradually decreasing, and there are various print quality defects appearing, such as toner smear, curl, and/or wave. The complete replacement procedure is included below.

The installation of a new fuser assembly unit in your HP LaserJet 1160 Printer includes the following removal procedures:
1. Covers removal (Left-side, right-side, back, and top covers)
2. Fan removal
3. Duplex-drive gears/face-down gears removal
4. Formatter removal
Each of the removal procedures is included separately below. Please follow the execution order strictly.

1. Removal of the printer covers
Left-side cover
Initially, you must open the door of the toner cartridge compartment, and then release the two right tabs of the left-side cover. After that, you must release the interlock tab by sliding the left-side cover towards the front side of the main unit, and then lift the cover away from the laser printer.
Right-side cover
You must carefully lift the back of the laser printer, and then release the tab, which is located at the bottom of the right-side cover. After that, you must release the two internal tabs of the right-side cover, and then lift the cover away from the laser printer.
Back cover
You must start the removal procedure by detaching the four screws, which are securing the back cover to the main unit. Then, you must flip over the main unit so that it rests on its front side. In the next step, you must release the right tab of the back cover, and then release the tab of the duplex tray by sliding the back cover toward the right side of the printer. Finally, you must remove the back cover from the main unit by pulling it carefully upwards.
Top cover
You must pull the release tab of the duplexer tray towards you, and then slide the duplexer tray towards the right side of the printer. After that, you must take the duplexer tray out from the main unit, and then remove the two screws from the rear side of the top cover. Now, you must remove the screw from the left side of the top cover, and then remove the screw, which is securing the front side of the top cover to the main unit. In the next step, you must lift the left side of the top cover up, and then detach the control panel cable. Finally, you must remove the top cover from the main unit.

2. Fan Removal
You must disconnect the fan cable from the main unit, and then remove the two screws from the chassis of the fan. After that, you must detach the fan clip, and then carefully remove the fan from the laser printer.

3. Duplex-drive gears/face-down gears removal
You must remove the three screws, which are securing the gear plate. Then, you must remove the gear plate along with the gears from the laser printer.

4. Formatter
In the first step, you must detach the flat cable from the bottom of the formatter, and then the four cables from the top side of the formatter. Now, you must remove the two screws from the Input/output cover, and then remove the six screws from the formatter plate. Finally, you must remove the Input/output cover along with the formatter plate and the formatter from the laser printer.

Installation of the new Fuser Unit
Once you have removed the Covers (Left-side, right-side, back, and top covers), the Fan, the Duplex-drive gears/face-down gears, and the Formatter, you must release the two gears from the right side of the printer by pressing their tabs, and then slide the gears off the shafts. After that, you must disconnect the cable, which is located below the power switch, and then disconnect the six cables from the ECU. Now, you must release the two cable holders from the right side of the main unit by sliding their tabs toward the center of the laser printer, and then detach the cables from the printer chassis. In the next step, you must disconnect the three cables from the left and right sides of the ECU, and then remove the left cable holder by gently pulling it towards you. At this stage of the installation, you must disconnect the cable, which is located above the power cable socket, and then pull it out of the cable holder. After that, you must remove the three black screws from the right side of the laser printer, and then remove the three black screws from the left side of the laser printer. Now, you must release the exhausted fuser unit from the frame by pulling it towards you while slightly pulling the top side of the printer chassis to the right, and then pull the right side of the exhausted fuser unit towards you. In the next step, you must detach the delivery roller shaft, and then remove the exhausted fuser unit from the laser printer. Once the exhausted fuser unit is removed, you must unpack the new component, and then insert its delivery roller shaft into the hole of the printer chassis. After that, you must push the right side of the new fuser unit towards the slot until the new component is firmly inserted. Finally, you must reinstall all previously removed components/parts by following the current procedure in reverse order, and then test your HP LaserJet 1160 Printer.