Coli Manual No. CM102 M16A1 RIFLE ARMORER/DEPOT MAINTENANCE AND REPAIR MANUAL REVISED JANUARY 1980 OLTColt Manual No. GM102 TABLE OF CONTENTS Section No. Title CHAPTER I—INTRODUCTION 1 General 2 Description and Data ‘CHAPTER II—REPAIR AND MAINTENANCE INSTRUCTIONS Repair Parts, Special Tools and Equipment Trouble: ting Maintenance Inspections CHAPTER III—AEPAIR INSTRUCTIONS CHAPTER IV—MATERIAL USED IN CONNECTION WITH MAJOR ITEM CHAPTER V—FINAL INSPECTION CHAPTER VI—REPAIR, REFINISHING AND RE. EMBLY Torque Requirements: “Barrel Nut (30 ft-lf) (4.15 kg m) “Flash Suppr -30 ft-lb) 40-0.48 kg m “Receiver Extension (35-39 ft Ib) (4.84-5.99 kg m} APPENDIX A—ARMORER'S TOOLS (See Page 3 For Tool List) APPENDIX B—REPLACEMENT PARTS LIST APPENDIX C—COMPLETE NUMERIC PARTS LIST *Use Combination Wrench, 62696, with Torque Wrench, 94162 “Use Wrench, 94154, with Torque Wrench, 94161Colt Manual No. CM102 Colt Manual No. CM102 LIST OF ILLUSTRATIONS UST OF TABLES Table No. Title No. Figure No. Title Page No. Page 11 M16.A1 Rifle (Right View) 1 241 Armorer’s Kit 3 1-2 M16 A1 Rifle (Left View) 1 2-2 Consumable Supplies Requirement 5 a4 Disassembly of Rear Swivel 16 23 Maintenance Inspections e 22 Headspace Check 16 a1 Guide to Maintenance Functions 19 23 Chamber Inspection WF 32 Cleaning and Lubrication 29 24 Firing Pin Protrusion Check 7 +3 Installing a Replacement Barral a1 ine Di 20 and Front Sight Assembly a a2 Disassembly of Upper Receiver Group: 21 a3 Disassambly of Lower Recelver Group 26 41 Bayonat-Knife Disassambly Ki) 61 Barrel Nut Installation 38 6&2 Bolt Carrier Kay Installation 39 63 Pivot Pin Detent Installation Procedure 40 4 Hammer Spring and Trigger Pin Installation 43 ASSOCIATED MANUAL os Receiver Extension ot en a The scope of this manual, CM102 is outlined on page 1. For unit maintenance aK C ing and operator's information and instructions on the 5.56 mm M16A1 Rifle, refer ne Combination Wrench 45 fo Colt Manual CM101 AS Reflector Tool 45 . Ad Headspace Gage 45. AS Punch Set for Front Sight Taper Pin Removal and Installation 46 AB Pivot Pin Detent installation Tool 46 AT Firing Pin Protrusion Gage 46 AS Punch Setter 46 Ag Bott Catch Pivot Pin Punch 47 aA10 Gas Tube Roll Pin Punch 47 Alt Pivot Pin Detent Depressor 47 A12 Front Sight Post Tools 4B Ala Barrel Removal Vise Jaws 49 Bi Upper Receiver Group s2 B2 Bolt Carer Group 4 63 Lower Receiver Group 56 B4 Sting Silent and Magazine 58 BS Rilfle—Exploded View: 59 ci Armorer's Kit 65Colt Manual No. CM102 CH 1 CHAPTER I— INTRODUCTION SECTION 1—GENERAL 1-1. Scope This manual provides spectfic instructions for the inspection and maintanance of the 5.56mm Rifle, M16A1; Bipod, U.S. Model M3; bayonet knife, M7; and scabbard, MBA1 by armorer and depot shop personnel. The information and instructions provided are normally beyond the scope of tools and equipment available to the operator and/or his operational unit. FIGURE 1-1, M16A1 RIFLE (RIGHT VIEW) FIGURE 1-2. M16A1 RIFLE (LEFT VIEW) Colt Manual Mo. CM102 Chit 1-2. Recommendations for improvement of thig Manual User reports of errors or omissions and recommendations for improving this Manual are encouraged. It is requested that such reports be submitted to: ‘Cott Industries Firearms Division 150 Huyshope Avenue (actors Connecticut 06102 SECTION 2—DESCRIPTION AND DATA 1-3. General Refer to Colt Manual No. GM101, Chapter |, Section 2, page 2, for a de- scription of the rifle and additional information.Colt Manual No. CM102 Chil Colt Manual No. CM102 Ch Il CHAPTER Il— REPAIR AND MAINTENANCE F INSTRUCTIONS TASLE 2-1, ARMORER'’S KIT, M16 & M16A1 RIFLE (Cont.) Colt Figure Page SECTION 1—REPAIR PARTS, SPECIALTOOLS, AND EQUIPMENT Too! PartNo. = No. No. Punch, Drive Pin (Gas Tube) 62697 AIO 47 2-1. Repair Parts Punch, Drive Pin—4/s2" 94154 AS 46 241.4 Repair parts for operator and unh maintenance are listed in Colt Punch, Drive Pin—¥4" 94155 22K 22 Manual No. CM101, Appendix B, page 64. Punch, Drive Pin—14" 94156 Par.6-2 37 241.1 Rlepalr parts for armorer and depot maintenance are listed and umen . Balt Catch pat Fin #2680 ag a illustrated in Appendix B, page 50 of this manual. . Taper Pin Starter songz AS 46 Punch, Taper Pin Insertion 62683 AS 46 2-2. Special Tools and Equipment Rod, Cleaning, 5.56mm | 62702 Al a“ The special tools and equipment requirad for the maintenance and repair ee page Mechanics wee oe x operations described in this manual are listed in Tables 2-1 and 2-2, Punch: 480 1D x 3%" 4 . Setter, — long 62688 - _ which follow, and in Appendix A, page 44 of this manual. Setter, Punch—190 ID x 31%" long 62689 _ _ Setter, Punch—190 ID x 6* long 62690 = _ TABLE 2-1, ARMORER'S KIT, M16 & M16A1 RIFLE 5 ; Punch—220 ID x 3%" long 62691 _ _ Colt Figure Page Setter, Punch—(with fiat) 82692 Aa 46 Tool Part No. No. No, Socket, Hex-bit Wrench Armorer's Kit, M16 & M16A1 Rifle 62675 ci 65 (with short bit) 94158 63A 39 Tool Box, Steel o14i4 C1 65 Tool, Alignment, Barrel Nut 62653 18 38 Brush, Bore Cleaning 94144 Ad 44 ‘Tool, Pivot Pin Detent Installation 62698 AB 46 Brush, Chamber Cleaning 94145 Al 44 Tool, Refiector, Chamber ‘62604 238 Aa 17 & 45 Punch, Genter 94146 6-28 ag Tool, Swaging, Rivet 62715 C1 5 Depressor, Front Sight Detent 62672 AIZ 4a Vise Jaws, Barrel Removal 62695 Ala 49 Depressor, Pivot Pin Detent 62673 Alt a7 Vise, Bench, Machinists 4" ‘Gage, Firing Pin Protrusion 62678 AT 46 (Optional) 94154 —_ _ ‘Gage, Headspace T27921 Ad 45 Wrench, Combination 62606 AQ 45 Wrench Handle, Flexible og147 +26 ai Wrench, Front Sight Post 62899 Al2 48 32P 22 Wrench, Socket Head Hex Screw 94160 6-24 39 2Q 23 Wrench, Torque Limiting, 44" Square Hammer, Ball Peen 8 oz. 94148 _ _- Drive 934161 G24 a9 Hammer, Ball Peen 16.0z. 4149 - - Wrench, Torque Limiting, %* Square Hammer, Soft Face 94150 = - Drive 94162 628 38 Phers, Extemal Retaining Ring 94151 225 23 Punch, Drive Pin—‘/16" 94152 32a 21Colt Manual No. CM102 Ch I TABLE 2-2, CONSUMABLE SUPPLIES REQUIREMENT Rem Mo. Nomenclature 1 2 3 ne 10 11 12 13 Cleaner, Tobacco Pipe Cleaning Compound, Rifle Bore (U.S. Federal Specification, P-C-111 or equivalent) Cleaning Compound, Solvent (U.S. Specification MIL-C-372 or equivalent) ‘Cloth, Abrasive: Crocus Ferric Oxide and Quartz ‘Grease, Molybdenum Disulfide (U.S, Speci- fication MIL-G-21 164 or equivalent) Lacquer: Black (jet) Lusterless Acrylic Nitro- ‘Cellulose type (touch up) (U.S. Federal Speci- fication TT-L-S0D, Type 1 or U.S. Specifi- cation MIL-L 19538; Color 37038) Lubricating Oil, Semi-Fluid (LSA), (U.S. Spaci- fication MIL-L-46000) Lubricating Oil, Automatic Weapons (LAW) (U.S. Specification MIL-L-14107) Lubricating Oil, General Purpose Preservative (U.S. Federal Specification V¥-L-800 or equivalent) Penetrating Oil (U.S. Federal Specification VV-P- 216 of equivalent) Rag, Wiping: Cotton Sealing Compound, “Permatex No. 3D Aviation Form-A-Gasket" (Permatex Co., Brooklyn, N.) ‘Swab, Small Arms Cleaning AR = As Required Note: The weapon is compatible with and will function properly using any good grade of oll and bore cleaner. The above formulations are recommended only because it is believed they are the best for all firearms, but equivalent ma- terials would be acceptable. Quantity AR AR AR AR Colt Manual No. CM102 Ch Il SECTION 2—TROUBLESHOOTING 2-3. General Troubleshooting instructions are contained in Colt Manual No. CM101 Chapter Ill, Section 5, page 52.‘Colt Manual No. CM102 Chil SECTION 3—MAINTENANCE INSPECTIONS 2-4. General This section provides specific instructions for inspection of material in the field ‘or in maintenance shops. Troubleshooting information is incorporated wher- ever applicable as a normal phase of inspection. 2-5. Purpose of Inspection Inspections are made for the purpose of: (1) determining the condition of an item as to its serviceability; (2) recognizing conditions that would cause failure; (3) assuring proper application of maintenance policies at prescribed levels; and (4) determining the ability of a unit to accomplish its maintenance and supply missions. 2-6. Categorias of Inspection The categories of inspection performed by direct and general support mainten- ance personnel are listed in paragraphs 2-7 and 2-8 following. For inspection procedures, refer to Table 2-3, page 9. 2-7. Inspection of Material in the Field This is the inspection of equipment to detect probable failure before unsar- viceability occurs; inspection to determine the availability and use of technical and supply manuals and lubrication instructions; inspection to determine the accuracy of records, authorized levels of aquipment and supplies, practices of supply economy, preservation, and knowledge of the proper procedures for requisitioning supplies and equipment, and follow-up thereon. 2-8. Direct and General Support Inspection 2-6.1 Initial Inspection. This is an inspection of material received in mainten- ance shops for purposes of determining the degree of repairs and parts re- quirements. This includes determination of modification work orders to be applied. ‘Colt Manual No. CM102 Ch Il 2-8.2 In Process Inspections. These are inspections performed in the pro- cess of repairing the material, to insure that all parts conform to the prescribed repair standards, that the workmanship is in accordance with approved methods and procedures, and that deficiencies not disclosed by initial inspec- tion are found and corrected. 2-6.3 Final Inspection. This is an acceptance inspection performed by a final Inspector, after repairs have been completed, to insure that the material is ac- ‘eptable for retum to user or for retum to replacament stock, according to established procedures. 2-9. Inspection Procedures ‘The inspection procedures for the rifle and bipod aHer disassembly are shown in Table 2-3, page 9, and specific instructions on inspection prior to disas- sembly are shown in paragraph 2-10 below. CAUTIONS: 1. ENSURE THAT MAGAZINE '§ REMOVED AND THE RIFLE IS NOT LOADED BEFORE STRIPPING, CLEANING OR INSPECTING SO THAT IT WILL NOT FIRE. - 2, WEAR SAFETY GLASSES IN CASE YOU LOSE CONTROL OF SOME SPRING LOADED COMPONENT WHICH COULD INJURE YOUR EYES. 3. DO NOT PERMIT LIVE AMMUNITION IN OR NEAR THE WORK AREA. 2-10. Inspection Prior to Disassembly NOTE: Check lo see that the rifle and accessories have been cleaned of all grease, oil, dirt, or foreign matter which might interfere with proper functioning ‘or obscure the true condition of the parts 2-10.1 Make an overall inspection of the rifle and accessories for general ap- pearance, condition and operation. 2.10.2 On material turned in for repair, make an initial inspection to determina the extent of repair required and the basis of procuring the parts or assemblies Necessary to accomplish the repair. 2-10,3 Refer to Chapter V, page 34 for functional inspections.Colt Manuva: “fo. GM102 Ch Il Colt Manual No. CM102 Chl TABLE 2-3—MAINTENANCE INSPECTIONS ‘TABLE 2-3—MAINTENANCE INSPECTIONS (Cont) Direct and General Direct and Field Support General Inspection inspection Action Reference Field Support Spot nie In inspection Inspection = Actlon Reference Check tial.» Process Spot ok In 1. MAGAZINE ASSEMBLY 8 rec ‘ Process (2) inspection den _ - Inspect for dents, cracks, or x x chic ertuioaa aentieeoacke Chipping that would impair the bent ips, oat cs functioning of camponartts or the damaged feeder lips or bent or weapon. broken basa plate retaining tabs. C. Barrel and Barrel Extension x x — _B. Check reararea of follower x x — 1) Inspect surfaces for cracks for chips or excessive wear or other defects. which would impair functioning of x x - (2) Check barrel extension for the bolt catch. burrs, or broken or wom locking x x — ©. Examine springs for breaks, lugs. corrosion, of improper x x — (3) Check bore for cleanliness fo the follower. and freedom from corrosion. 2. UPPER RECEIVER GROUP x x _ (4) Individual pits as large in A. General diameter as a land or groove x x — — (1) Inspect for cracks or mutila- only. wntomayine pis ae tion which would affect function. acceptable in the bore. ‘Small dents or gouges should . me not be cause for rejection. x x =_ (5) When viewed with the naked , lands that appear dark due x x — (2) Inspect all parts for wear or iGeoating of gicing metal rom damage. jac . projectiles are allowable. x x X (3) Check springs for breaks or x x — (6) Definitely ringed bores or deformations. bores ringed sufficiently to bulge B. Handguard Assembly ‘the outside surface of the barral x x — (1) Inspect for breaks and sap- are cause for rejection. aration of handguard from liner.‘Colt Manual No. GM102 Ch II TABLE 2-3—MAINTENANCE INSPECTIONS (Cont) Direct and ‘General Field Support Inspection Inspection Spot Ini- In Check tial Process x x - x x _ x x - Qreally assist in this inspection. Appreciable erosion can exist and the rifle may still target satisfactorily. Target group size obtained by test firing should be the final criterion used to judge the acceptability of the barrel. The menximnum permissible group size should be established by the user, (8) Inspect chamber for cleanli- ness and freedom fromcarhon = — Figure 2-3, deposits and corrosion. page 17 (10) Inspect chamber for pitting Figure 2-3, using chamber reflecting tool, page 17 pin 62694. Position tool in cham- ‘ber as shown in Figure 2-3. ‘Slowly rotate the upper recelver ‘50 that the reflected light will iuminata the chamber wails. A pit or pits as large as 1/32 inch (0.794 mn) in diamter shall be cause for rejection. A small number of uniiormly fine pits, (approximatety.010 In. (0.254 mm diamter) shall be accept- able provided that cartridges fired in the weapon do not exhibit Cases with unusual or noticeable deformation or marking of the case body or excessive offsat of the extractor groove flange. i ‘Goh Manual No. OM 102 Ch Il TABLE 2-3—MAINTENANCE INSPECTIONS (Cont) Direct and General Field Support Inspection Inspection Spot ini In Gheck tal =Process: x x x x x = x x _- x x _ x x _- x x _- x x x x x x x x x x _- x x - 3. BOLT CARRIER GROUP x x _ x x - Reference (11) Check headspace, using = Figure 2-2, Headspace Gage T-27921, page 16 D. Front Sight and Gas Tube (1) Check front sight for cracks and general condition. (2) Check front sight post and Gatent for rust or other defician- cies which could cause restricted movement. (3) Check gas tube for cracks, deformities, or eccentric wear at rear tip. E. Ejection Port Cover Assembly (1) Check for bent. twisted or dented cover. (2) Check detent, and C ring for breakage of corragion. (3) Check for broken, or dis- torted cover spring. F Forward Assist. Check for corosion and free function. G. Rear Sight. Check for broken or corroded windage drum and for cormosion between sight leaf and receiver. A. Check for cracks or deformi- tes in bolt (cam pin hole area}. B. inspect bolt for pitted or ‘chipped bolt face, elongated firing pin hole, or comoded ejector. 12‘Colt Manual No. CM102 Ch I TABLE 2-3—MAINTENANCE INSPECTIONS (Cont) Direct and General Field Inspection Spot Check x Support Inspection = Action Ini tial x In Process x C. Each holt locking lug should be inspected periodically for cracks. Use a black light it available, otherwise use 4 glass of no more than 3X magnifica- tion. Particular attention must be given to the lugs adjacent fo the extractor slot, particularly where the rear shoulder of the lug meets the bolt body. Bolt with lugs exhibiting cracking, or which are definitely suspect, will be replaced. D. Inspect for broken bolt rings and proper spacing in ring gaps. Ring gaps are to be staggered to prevent loss of gas pressure. Check affectivaness of rings as follows: With firing pin and cam pin removed, and bol assembled to bolt carrier, hold carrer vertically with key pointing downward. Bolt should not drop out of carrer; If bolt drops out, replace belt rings. E. Inspect firing pin for wear and burrs. F. Check firing pin protru- sion, using gage 62679. Protrusion should be between 0.028 & 0.036 in. (0.711 mm- 0.914 mm). G. Check key and bolt carrier assembly for cracks, buITs, chips, rust, or blockage of the key bore and gas passages, and fora bent or dented carrier key. Figure 2-4, page 17 13 Colt Manual No. CM102 Ch Il ‘TABLE 2-3—MAINTENANCE INSPECTIONS (Cont) Fleid Inspection Spot Check x x 4, LOWER RECEIVER GROUP x Direct and Support Inapection Action in- tal = Process x x x General x x In H. Check socket haad cap Figure 6-2, screws. They must be properly page 39 tightened and staked. Check for” evidence of gas leakage be- tween camer and key. |. Inspect extractor assembly for cracks in the claw areas, glon- gated pivot holes, a bent or broken extractor spring, and damaged or missing rubber plug. J. Check for broken extractor A General (1) inspect for cracks, corrosion or mutilation which would affect functioning. Smail dents or gouges will not be cause tor rejection. Coroded areas should be noted for immediate repair. (2) Inspect all parts for wear and damage. (3} Check springs for breaks or deformation. (4) Check trigger pull, thinimum 5.5 Ib., maximurn 8.5 Ib (2.49 kg- 3.B6 kg). B. Stock Assembly (1) Inspect for breaks and sepa- 14‘Cat Manual No, CM102 Chil TABLE 2-3—MAINTENANCE INSPECTIONS (Cont) Direct and General Fleid Support Inspection Inspection Action Reference Spot Ine In Chack tial = Process x x — (2) Inspect for dents, cracks and chipping that would impair the functioning of components or weapon, 5. BIFOD AND CASE x x — _A Inspect tha bipod legs: they shall move freely from closed to ‘open position under spring ten- ‘sion. Inspect for rust and shiny areas. Any found must be towched-up. x x _ B. Bipod must hold securely to the rifle. x x G. Check case for holes or tom stiches 6 BAYONETANDO SCABBARD - x x — A. Inspect bayonet for chipped or broken grips, missing grip screws, bent, rusted, or missing latches. Latches must open and close freely and bayonet must hold securely to carbine. x x — — B. Inspect scabbard for missing fivets, tom webbing, broken or cracked body and tom or missing lace. Check that snap fastener holds firmly, 15 & REMOVING SWIVEL RETAINING SCREW rn TEA en a MLATION Colt Manual No, OM102 Ch II FAGURE 2-1 DISASSEMBLY OF REAR SWIVEL Eid B. REAR SWIVEL REMOVED FIGURE 2-2, HEADSPACE CHECK B. HEADSPACE GAGE INSTALLED = ee €. BOLT INSTALLATION D. PROPER HEADSPACE INDICATION BOLT WILL NOT GO TO LOCKED POSITION. 16‘Cott Manual No. CM102 Ch Il Colt Manual No. CM102 Ch if CHAPTER Ill— REPAIR INSTRUCTIONS #1. General A. This section contains repair instructions and authorized girect and general suppor! maintenance in the removal, disassembly, cleaning, mspection, lubri- ‘cation, repair, and assembly of major groups and agsembkes for the M16A1 Rifle and its accessorles. . B. Refer to Table 3-1, page 19, for guide to maintenance functions. G. Disassemble in accordance with the Instructions contained in Colt Manual No. CM101, page 31, and Figures 3-1, through 3-3, pages 20-28 of this manual. +2. Replacement of parts ‘Replace all parts thal are wom, damaged, cracked or broken. All replacement arts are interchangeable and require no adjusiments at installation. How- ever, to insure proper function and reliability, the following precautions should be taken: 3421 Oo not interchange bolts and bolt carriers unless replacement is neces- 3-2.2 If replacement of either part becomes necessary, carefully check the FIGURE 24. FIRIGG PIM PROTRUSION CHECK new part io s6e that il fils property, operates smoothly, and that the proper head space is provided (See Figure 2-2, page 16). 323 Hone or more rings of the bolt assembly are damaged, replace the three rings as a set. 22.4 When assembling 2 bolt with new rings into the bolt carrier, rotata the bott while pushing it into the carrier to prevent damaging the rings. Move the bolt in and out several times to seat the rings. 32.5 ithe bott carrier kay is replaced, it may be necessary to creale a seal between the bolt carrier and key by firing 5 fo 8 rounds. (Manual operation of 8. FARING PIN PROTRUSION CHECK the rifle may be required.) Sealing compound (Table 2-2, item 12, page 5.) (GAGE (P/4 62879) may also be required prior to assembly of the key and bolt carriar. (See Chap- fer V1, paragraph 6-2.1.4 page 39.) 32.6 See page 31 for installation of replacement barrel and front sight assembly. B. CHAMBER VISUAL INSPECTION NOTE: With the firing pin held firmly forward in the bolt, the end of the firing pin Protrusion gage marked “MAX” (‘GO"—.036 in, 0.91 mm) should pass over the end of the pin (Sea Figure 2-4) without touching it, and the end marked “MIN” {‘NO-GO" —.028 in, 0.71 mm} should hit the end of the firing pin and not pass over it 17 18‘Coh Marwal No. CM102 Gh Ili Colt Manual No. OM102 Ch Hil FIGURE 3-1. MAGAZINE DISASSEMBLY “Aqua ayea po E7 Las TCR DUR UPC PUR Reson Bu UD KuenovOLR ‘eed 30 eNO NY “CS ‘eupn 70 eid we Buyer Buje puw weer ‘upd ond ap ence “E "BUNOU pe 10) MDE CL AOR PUP Yeon Bate} punodwas Buyvouliy Logue 20 vee 4909 e790 Bure qeued 10 neuieRUCG w 4 480j9001 JAM JO UOILON PUBALEY Bom “y {MOR HF PEUTIC OC P}NOINE Bude LN ugep ad ond powure! jo eErm neg eoLRURUIBU: FUR Oy POUITISH BUDCERIK ‘SLLON SNOLLONNA JONYNELNIVA OL S0IND ‘}-¢ S1G¥L + Tewa'es we | ogee wa crrer'es | pata v | posers mewewdy | eae ad aea't-9 amg | Sider | gue Bag't+ eg | pum uateg | ee | ancy LON og) opeted Dad LERul eu'eL-EPu | dea'titoue wed O-EDUn sated waver | erdeermd | een | mee'ee Bs tree Wid’ td led'ee wd | eel W 8 ae ~_ | oeeted ‘Ose Gpue | dsu'citeue | Graiigewt | rao co dro arene | eed e Gd | Bo eraeemg | rete | eat md | eee eum UD OR —_—_i— —— | eee | SSdiev-epun | osucreoue | eruiigpur | rra'ole pun neg Stand | ceded) cto | aces) preeeag | uaaomd | erst | na'romd ante t j | i in + + | O6a'ret pun brah 8 Ue | Arguvemey Waits craked | recta | itdeeued | cewee oe | gta'DEe | i Sa | suet yee Atnetery | Burm | Aquneresig | Auerny ‘voROpN] Bue | Squesseng | uopery | ui | | ewour BED "ON TNH L102 | LOL-H89 "OW THN L103, 19Colt Man...’ “lo, CM102 Ch lil FIGURE 3-2. DISASSEMBLY OF UPPER RECEIVER GROUP r PUNCH, "fie (PIN 94152) A. CHARGING HANDLE ROLL PIN REMOVAL ad Coll Manual No, CM102 Ch Ill FIGURE 3-2. DISASSEMBLY OF UPPER RECEIVER GROUP (Cont) B. CHARGING HANDLE LATCH DISASSEMBLED, COMBINATION WRENCH (P/N162696) HANDLE FLEX {PIN 94147) C. FLASH SUPPRESSOR REMOVAL (FOR ASSEMBLY TORQUE SEE PAGE 33) PUNCH SET, FIG. AS, PAGE 46 | \ | _ DB. FLASH SUPPRESSOR REMOVED wl (Starter punch Is shown; the intermediate punch 1 E. FRONT SIGHT TAPER PIN REMOVAL js then used, and taper pins are finally removed using the knock out punch.) EE FRONT: MOVE! TAPER PINS: HAMMER (PIN 94150) AS REQUIRED \ Po G. FRONT SIGHT REMOVAL 2i H. FRONT SIGHT REMOVED J. GAS TUBE ROLL PIN REMOVAL (les” PUNCH, P/N 62697) Note: The swivel is attached by a rivet. The rivet may be removed by drilling off the flared end and punching out the remaining shank. When installing a new rivet, flare the end using the tool, swaging, rivet. (P/N 62715) K. FRONT SWIVEL RIVET REMOVAL (¥a" PUNCH, P/N 94155) L. FRONT SWIVEL REMOVED a M. FRONT SIGHT POST REMOVAL (WRENCH, P/N 62699, DEPRESSOR, P/N 62672) 10. FRONT SIGHT DETENT AND SPRING REMOVED N. FRONT SIGHT POST REMOVED P_ BARREL NUT REMOVAL (WRENCH HANOLE P/N 94147 COMBINATION WRENCH P/N 62696) 22Colt Manual No. CM102 Ch Ill FIGURE 3-2. DISASSEMBLY OF UPPER RECEIVER GROUP (Cont) ei A. BARREL REMOVED Q. BARREL REMOVAL (FOR ASSEMBLY TORQUE SEE PAGE 37} ‘Colt Manual No. CM102 Chill FIGURE 3-2. DISASSEMBLY OF UPPER RECEIVER GROUP (Cont) DETENTAND SPRING ¥. WINDAGE DRUM REMOVED: Z. WINDAGE SCREW REMOVAL "(Also remove detent and spring) EXTERNAL RETAINING RING PLIERS (P/N 94151) Oo6 @| 7. BARREL NUT OISASSEMBLED AA. WINDAGE SCREW AND SIGHT LEAF REMOVED PUNCH, 4szin. © (P/N 94154) U. EJECTION PORT COVER PIN REMOVAL (Alternatively, if barre! is not to be removed, remove C clip from front of pin and withdraw pin AC, FORWARD ASSIST ASSEMBLY AD. FORWARD ASSIST ASSEMBLY ROLL PIN REMOVAL REM to rear} Se N ¥ PUNCH "hs" (PIN 94152) W. WINDAGE DRUM ROLL PIN X. WINDAGE DRUM ROLL PIN REMOVAL REMOVED 23 AF FORWARD ASSIST PAWL DISASSEMBLED AE. FORWARD ASSIST PAWL ROLL PIN REMOVAL 24Colt Manual No. CM102 Ch Ill FIGURE 3-2. DISASSEMBLY OF UPPER RECEIVER GROUP (Cont) WRENCH (PIN 94160) 7 AG. BOLT CARRIER KEY REMOVAL, (FOR ASSEMBLY TORQUE SEE PAGE 38) Fer bolt carrier disassembly see CM101, figure 3-3, page 33. Note: The staked sockel head screws may ba difficult to ramove. Ho, file off sufficient 3 i staked Material to remove screws and replace key and screws with new components, 25 ‘Colt Manual No. CM102 Ch Ill FIGURE 3-3. DISASSEMBLY OF LOWER RECEIVER GAOUP » A. REAR SWIVEL SCREW AND BUTTPLATE REMOVAL 8. REAR SWIVEL & BUTTPLATE REMOVED WRENCH, ADJUSTABLE, OR WRENCH, COMBINATION P/M 62596 AND HANDLE, FLEX, PIN 94147 ont C. LOWER RECEIVER EXTENSION REMOVAL D. LOWER RECEIVER EXTENSION REMOVED CAUTION: DETENTS AND SPRINGS ARE UNDER TENSION AND WILL FLY OUT OF THE HOUSING UNLESS CAREFULLY CONTROLLED.Colt Manual No, CM102 Ch Il! FIGURE 3-3. DISASSEMBLY OF LOWER RECEIVER GROUP (Cont) , PUNCH, Yin, (PIN 94155) F. TRIGGER GUARD ROLL PIN REMOVAL. DETENT 7 SPRING €. REMOVE/INSTALL DETENT AND SPRING. PUNCH (PIN 62680) H. BOLT CATCH PIN REMOVED M. AUTOMATIC SEAR REMOVAL Jd. BOLT CATCH SPING AND PLUNGER REMOVED 27 Colt Manual No. CM102 Ch til FIGURE 3-3. DISASSEMBLY OF LOWER RECEIVER GROUP (Cont,) K. PISTOL GRIP REMOVAL MN. SELECTOR LEVER REMOVAL 28Cott Manual No. CM102 Ch Ut 3-3. Cleaning and Lubrication Clean and lubricate the material as instructed in Col Manual No. CM101, Paragraphs 3-5, page 41. Also comply with the additional instructions in Table 32 below. TABLE 3-2—CLEANING AND LUBRICATION hem Action Required Barrel hard carbon is still evident in the chamber after clan ing, dip soak chamber and reciean. Dry thoroughly with swabs. Barrel Nut A. Remove all evidence of dirt or rust. Assembly B. Prior te assembly, apply a coaling of LSA cil to com- ponents of barrel nul assembly with the exception of the barrel nut thraads which should be coated with motyb- denum disulfide grease. Front Sight Apply a generous coat of LSA oil to the front sight post, Assembly detent, and spring prior to assembly, Gas Tube. Aemove carbon deposits from the exterior surface of the tube. IMPORTANT: Do not use any type of abrasive material to ¢lean the gas tube. A .069 in (1.60 mm) to .076 In. (1.99 mm) diameter spring wire may be used to dislodge de- posits inside the tube. Upper Receiver AL Apply a generous coat of LSA cil to all intemal Group surfaces and a light coat io all external surfaces prior to assembly. IMPORTANT: Do not use a wire brush on aluminum sur- faces such as the receivers. B. Prior to assembly. thoroughly lubricate the ejection port cover, and ail componants of the forward assist and front sight assembiies with LSA oil. NOTE: The ejection port cover latch shall not be disas- sembled. Hf the latch is inoperative, the ejection port cover assembly must be replaced. ‘Colt Manual No. GM102 Ch iil TABLE 3-2—CLEANING AND LUBRICATION (CONT) Hem Action Required Bolt Carrier A. Clean the extractor recess in the bolt. Group 8. CGlasn the gas exhaust ports in thetbott carter with a hand-held No. 36 drill (.106 in, 2.69 mm). . Lower Recalver A. Prioric assembly, apply a generous coat of LSA ail to Group all functioned parts. B. Lubricate the threads of tha lnwer receiver extension with a coat of molybdenum disulfide grease. NOTE: Dry cleaning solvent may be used to clean or wash grease or oll fron all parts af rifle and bipod. General ‘Component parts which contain a hard carbon, such as the flash suppressor, barrel bore, bok carrier group, will require special cleaning using carbon removing compound. GAUTION: FOLLOW SAFETY PRECAUTIONS FOR HANDLING CARBON REMOVING COMPOUND TO PREVENT SKIN OR EVE DAMAGE A. Filla suitable container with fresh compound. B. Remove all grease, dirt and of before soaking com- ponents in compound. Completely immerse parts to be leaned in compound. ‘C. Soak for? to 16 hours. Ramove parts and allow to drain. Rinse in dry cleaning solvent. Brush with a stiff briatie brush under running water to effectively ramove- carbon.Colt Manual No. CM102 Ch Ill Table 3-3 INSTALLING A REPLACEMENT BARREL AND FRONT SIGHTASSEMBLY When installing a replacement barrel and front sight assembly, part no. 62744, Note that it includes the barrel, front sight assembly, barra! nut and cap: handguard. See item no. 5.on Figure B-1, page 52 for illustration of components. Step Action Reference 1 CLEAR RIFLE 2 Disassemble by separating re- M101, Par. 3-4, page ceivers andremoving boltcarrier = 31, staps A, Band G assembly and charging handie. 3 Remove flash suppressor and (M102, Fig. 3-2, page Jock washer and retain for as- 21, steps C and D sembly on new barrel. 4 > Remove gas tube roll pin. M102, Ch. Ill, Fig. Remove gas tube by pushing it back through barrel nut until front end is Clear of front sight assem- bly and cap handguard. Then, pull gas lube clear and forward oul of the barrel nut Retain gas tube for assembly to new barrel and ensure that it isnot bant or dented. +2, page 22, step J 68 Remove barrel nul and barrel M102, Ch. Ill, Fig. from upper receiver. 3-2, page 22 and 23, steps PQ, and A ‘When assembling barre! and M102, Ch. IV, Fig. barre! nut to recaiver use the 6+1, page 36, steps barrel nut aligning tool which A, Band Cc must be installed in the carrier key. 7 Disassemble barrel nut. compo- M102, Ch. Ill, Fig. nents leaving barrel nut on. 3-2, page 23, steps barrel. Retain snap ring, hand- SandT guard; slip ring, handquard; and spring for new barrel nut. Install replacement barrel and front sight assembly, and reassemble rifle by following this procedure in reverse order and the instructions given for installing a barrel. CM102, Ch. IN, par 6-2.1.2 page 37 31 Colt Manual No. CM102 Ch iv ‘CHAPTER IW—MATERIAL USED IN CONJUNCTION WITH MAJOR ITEM 41. General Tha Bayongt-Knite, U.S. Model M7: and#iizyonet-Knife Seabbard, U.S. Model M3A1, are used in conjunction with the major ttem. Refer to Manual CM101 for operator and organization maintenance instructions. 42. Direct and General Support Maintenance 42.1 Disassembly. Refer to Figure 4-1, page 33. NOTE: Prior to disassembly, it is recommended that the right hand release and plate be marked to assist in identification when assembling the left and right hand releases (See Figure 4-1, page 33). 422 Cleaning. Refer to Manual CM101, page 31. 42.3 Inspection and Repair 2.3.1, Bayonet-Knife (a). Replace screws, if threads are stripped. b}. Replace cracked grips. Fy Replace spring pin if worn or dam: . . Replace spring if kinked, set, or broken. fe). Remove nicks and dents, a3 required by grinding and/or stoning. {f). if wear is noted on the release camming area and positive ratantion to the rifle is questionable, replace as required, If binding is noted due to a bent release, repair by straightening or replace release, {a)- Use flat black lacquer if shiny surfaces are on handle of blade. 4-232. Bayonet-Knife Scabbard, U.S. Model MBA1. (a). Metal parts will be dark. If the finish of metal is worn, flat black lac- quer may be applied. (b). ithe scabbard is chipped, exposing the fabric or the surface Is scratched or marred, smooth as raquired and paint with olive drab lustarless enamel. {e). Clean and/or replace broken or damaged lace.Colt Manual No. CM102 Ch Iv FIGURE 4-1. BAYONET-KMIFE DISASSEMBLY (C, RELEASE INSASSEMBLY D. RELEASE DISASSEMBLED 4-2.4 Assembly. Assemble by reversing procedure in Figure 4-1. Colt Manual No. CM102 Ch V¥ CHAPTER ¥—FINAL INSPECTION 5-1. General This chapter contains instructions for the final inspection of repaired rifles and bipods. As applicable, the rifles and bipods must be checked in accordance with the procedures outlined in Table 2-3, page 9, and in paragraphs 5-1.1 (through 5-1.3 which follow. Rifles that have been repaired shall be function fired to assure proper function. Rifles that have been rebarreled should be both function fired and fired for accuracy. 51.1 Visual inspection ‘Overall appearance shall be approximately that of a new weapon. All ex- Posed metal surfaces are to have a dull, rust or cormmsion resistant finish with ng burrs or deep: scratches. Barrels must be straight, clean, free of rust, Powder fouling, jarge pits, bulges, or rings. Fine pitting is allowable. Rifias must be complete with no missing parts. The serial numbers must be legi- ble. All stee! parts must be tree of rust. Roll pins must be secure and screws must be fight. Check to be sure that all modifications authorized to date have been incorporated. 3-1.2 Functional Inspection The instructions for accomplishing a functional inspection are contained in ‘Colt Manual No. CM101, Chapter Il, Section 5, page 25. 51.3 Inspection of Critical Dimensions Inspect for dimensional acceptability of headspace, firing pin protrusion, barrel straightness, and extent of barrel erosion in accordance: with the in- structions contained in Table 2-3, page 9.Colt Manual No. CM102 Ch VI ‘CHAPTER VI—AEPAIR, REFINISHING, AND REASSEMBLY 6&1. Repair and Refinish Procedures Approved procedures for repair and refinishing of various surfaces of the rifle 1.1 Repair Procedures The recommended repair procedures are by the application of touch-up coat- + ings and/or replacement of parts. NOTE: Stoning in accordance with standard shop procedures is in non-critical areas for removal of minor burrs, Micke or alight sutfece unper- factions. Extreme care must be exercised to preclude alteration of critical characteristics. Touch-up of the stoned surface should ba done as soon as possible after stoning or other abrasive procedures to prevent contamination 1 or corrosion of the exposed surface. 61.1.1 Dents and Gouges (A) Smooth the periphery of the defect by filing, scraping, sanding, buffing, or other appropriate means to improve the appearance and to establish a clan, firm contact area for the touch-up material. {B) Wash the area with solvent cleaning compound (Table 2-2, item 3, page §) to remove all dust, grease, or other foreign particles. {C) Dry the surface, apply the touch-up finish, and cure it in accordance with the instructions furni: by the manufacturer. The lacquer in Table 2- 2, item 5 page 5 should be used on all exposed, exterior surfaces of alumi- num parts. The touch-up lacquer may also be used on clean steel surfaces which are exposed and are not subjected to haat. 61.1.2 Coroded Components Corroded components, poartlouterly the upper and lower receiver exten- sion, may be repai ramoval of tha corrosion is possible by light sanding br puting, erating which will return the affected surface to a. smooth condition for touch-up. Affected area shall be cleaned and refinished as specified in paragraph 6-1.1.1 above. We Colt Manual No. CM102 Ch VI 6-1.2 Corrective Action for Unusual Malfunctions Cartridge Case Rim Shear the case cannot be removed from the chamber by the standard procedure {actuation of the bolt assembly), a cleaning rod may be inserted Into the muz- .. de and the case may be pushed out of the chamber, H the chamber is found to be pitted, replace the barrel and front sight assembly.Golt Manual No. CM102 Ch VI 6-2. Reassembly Reassembly of tha major groups shall include all necessary adjustments, Spacified torque applications (as indicated, using property calibrated and maintained equipment), and a constant quality assurance surveillance to in- sure that included parts, components, subassemblies, and/or assemblies conform to all criteria as specified in this manual. Torque wrenches listed in Table 2-4, page 3, shall not be considered as mandatory. However, the wrenches listed, with lheir inherent functional characteristics should fully sat- isfy all requirements contained in this manual. When installing the various roll pins, the % in, punch (pin 94156) shall be used in all cases in order to avoid damaging the ping or driving them in tog far. NOTE: LSA oil or equivalent shall be applied to all moving contact surfaces during reassembly. Emphasis is directed to all coil springs, particularly detent Springs, and associated detents, plungers, and/or retainers. The fire control selector must also be lubricated at assembly. The material shall be reassembled as spacified in the following paragraphs. 62.1. Upper Recelver Group The upper receiver group shall be reassembled by reversing the disassembly procedure and in accordance with the following instructions. 2.1.1 Front Sight. Visually align front sight taper pin holes before installation of new taper pins. Install pins from right side with uniform application of forea, using punch, p/n 62682. Support the front sight on a block of wood. Force applied shall not cause larger end of taper pin to enter to the point of being flush with sight frame surface, However, leading or small end of taper pin shall be flush or above sight frame surface atter application of above force. 62.1.2 Barrel. During installation of barrel assembly into the upper receiver, extreme care must be exercised to preclude damage to the upper recerver alignment slot by the barrel assembly alignment pin. Pin must enter slot, without deforma- lion of the slol walls, to the depth necessary to accomplish full contact be- tween the barrel assembly collar and the receiver. The threads of the barrel ful and the receiver shall be coated with molybdenum disulfide grease, page 5, item 5, prior to assembly. Initial torque applied to the barre! nut shall be 30 tt Ibs (4.15 kg m) using torque limiting wrench, p/n 94162, and the cembination wrench, p/n 62696, and with the barrel held in the barrel re- moval vise jaws, pin 62695, in a bench vise. (See Figure 6 1B.) Additional torque shall be applied as necessary to create clearance for free entry of the gas tube through tha barrel nut, using the barrel nut alignment tool, pin 62693, as shown in Figure 6-1A and C. a7 Colt Manual No. CM102 Ch vi FIGURE 6-1. BARREL NUTAND GAS TUBE/FRONT SIGHT ASSEMBLY INSTALLATION 4 . i i! \\was femme 5. BARREL NUTALIGNMENT TOOL (P/N @2683) INSTALLED IN KEY. A. BARREL NUT TORQUING* ©. BARREL NUT INSTALLED AND ALIGNED. 0B. GAS TUBE AND FRONT SIGHT ASSEMBLY INSTALLED. “MOTE; MAKE CERTAIN ALL THREE PINS OF THE COMBINATION WRENCH ARE FULLY ENGAGED WITH THE BARREL NUT.Colt Manual No. CM102 Gh VI Colt Manual No. CM102 Ch VI 6-2.1.3 Flash Suppressor Install the flash suppressor and lock washer with a torque of 25-30 ft bs FIGURE 63. PIVOT PIN DETENT INSTALLATION (4.15-5.53 kg m), using the combination wrench (Pin 62696) and the torque limiting wrench (p/n 94162), wilh the barre! held in the barrel removal vise jaws (p/n 62695) in.a bench vise. 6-2.1.4 Bolt Canier Group See Colt Manual GM101, page 33, for assembly instruction. When installing notion the boll carrier key, apply a thin coal of sealing compound (Table 2-2, item 12, page 5) to the undersurface of the key, being careful not to plug the gas port. Tighten the lwo socket head cap screws to a torque of 35-40 in. Ibs . (0.40-0.46 kg m) using the torque limiting wrench (p/n 94461) and the socket head hex bit wrench socket (p/n 94158) as shown in Figure 6-2a. The Iwo socket head screws shall then be staked to the key at two points ‘ using the center punch (p/n 94144) as shown in Figure 6-2b below. FIGURE 6-2. BOLT CARRIER KEY INSTALLATION 7 A TORQUING KEY SCREWS B. STAKING KEY SCREWS. (35-40 IN. LBS.) 2.1.5 Lower Receiver Group See Coll Manual No. GM 101, page 50, for assembly instructions which are . not included in this manual. Refer to Figure 6-3, page 41, for installation of the pivot pin detent and spring using the pivot pin detent installation tool. Particular care should be exercised during installation of the hammer as- sembly to insure that the ends of the hammer spring are resting on the up- per surface of the trigger pin as the hammer spring acts as a relainer for the trigger pin. (See Figure 6-4, page 42). (See Figure 6-5 for receiver exten- sion and buttstock installation.) A. DETENT AND DETENT SPRING INSTALL ATION. 39 Ss mm Coit Manual No. CM102 Gh ¥1 FIGURE 6-3. PIVOT PIM DETENT INSTALLATION (CONT) 8, PIVOT PIN INSTALLATION Action Insert the pivot pin detent installation tool (p/n 62699) in the pivot pin holes of the lower receiver as shown in Figure 6-34. Slide the installation tool in sufficiently to locate its hole directly over the detent cavity. Ingert detent spring and detent through the hole in the installation too! and into the detent cavity. Press the detent into the cavity with the 3/32 in. punch (pin 94154) but stop the punch just at the top of the cavity, Rotate the installation tool and punch 90°. Hold the pivot pin firmly against the installation tool and push the instal- fation tool out as shown in Figure 6-35. Rotate the pivot pin until the pivot pin drops into the pivot pin detent groove, at (Colt Manual No. CM102 Ch Vi FIGURE 64. HAMMER SPRING AND TRIGGER PIN INSTALLATIONColl Manual No. CM102 Ch VI FIGURE €-5. RECEIVER EXTENSION AND BUTTSTOCK INSTALLATION A. INSTALL DETENT AND SPRING, &, SCREW RECEIVER EXTENSION ONTO ¢. TIGHTEN LOWER RECEIVER EXTENSION RECEIVER. ENSURING THAT BUFFER RETAINING DETENTIS SECURE BUT FREE TO MOVE IN ITS: HOUSING.” "IT 1S RECOMMENDED THAT THE RECEIVER EXTENSION BE TORQUED TO 35-39 FT LBS (4.84-5.29kg m} USING TORQUE WRENCH 54182 COMBINED WITH WRENCH 2420. > D. REAR SWIVEL & BUTTPLATE E— REAR SWIVEL SCREW AND BUTTPLATE INSTALLATION. SECURED. 43, Coh Manual No. CM102 App A APPENDIX A BORE AND CHAMBER CLEANING TOOLS BRUSH, CHAMBER (P/N 94145) MASP NALEAD SPs as BRUSH, BORE (P/N 94144) SWAB HOLDER SECTION ae ROD SECTION. HANDLE ASSY (STOWED POSITION) OD, CLEANING (P/N 62702) HANDLE ASSY (FOLDED FOR CLEANING CHAMBER) HANOLE ASST (UNFOLDED FOR CLEANING BORE) FIGURE A-1, GORE AND CHAMBER CLEANING TOOLS.‘Colt Manual NO. CM102 App A PUNCH P/N 62683 (INTERMEDIATE) Colt Manual No. CM102 App A FIGURE A6. PIVOT PIN DETENT INSTALLATION TOOL (F/M 62698) (SEE FIG. &-3A, PAGE 40 and 6-38, PAGE 41) RECEIVER EXTENSION ayn SUPPRESSOR (NARROW DESIGN) (RIFLE ONLY) PUNCH NOT USED ON CARBINE. P/N Dd1Sa orn NUT (KNOCK-OUT) PUNCH P/N 2682 (STARTER) FIGURE AS. PUNCH SET FOR FRONT SIGHT ‘TAPER PIN REMOVAL ANDINSTALLATION RECEIVER EXTENSION (SEE FIG. +-2E, PAGE 21) (WIDE DESIGN) (RIFLE ONLY) DRIVE HOLE, Nore USED ON CARBINE. TORQUE WRENCH FIGURE A2. COMBINATION WRENCH eo 62696) (SEE FIG'S 3-20, PAGE 21, 3-2P, PAGE 22 and 3-20, PAGE 23) La — FIGURE A7. ar PIN PROTRUSION GAGE (SEE ae oe PAGE 17) \ FIGURE A3. REFLECTOR TOOL FIGURE A4. wen GAGE (PIN 62694) (Pi 7921) (SEE Oe Be PAGE 16) 45 46 FIGURE AS. PUNCH SETTER (P/N 62682) (WINDAGE DRUM ROLLPIN}‘Colt Manual No. CM102 App A i Colt Manual No. CM102 App A FIGURE AS. BOLT CATCH PIVOT FIGURE A10. GAS TUBE ROLL PIN PUNCH (P/N 62680) PIN PUNGH (P/N 62687) (BEE FIG, 33K, PAGE 28) (SEE FIG. 3-2J, PAGE 22) DEPRESSOR P/N 62672 FIGURE A12, FRONTSIGHT POST TOOLS. {SEE FIG. 3-2M, PAGE 22) FIGURE All. PIVOT PIN DETENT DEPRESSOR (P/N 62673). 47 46Colt Manual No. CM102 App A. Colt Manual No. CM102 App B APPENDIX B REPLACEMENT PARTS LIST Figure No. Page Nomenciature Part No. UPPER RECEIVER GROUP Bi-1 52 Charging Handle Assembly 62290 B1-2 52 Pin, Roll Latch, Pivot™ 95913 B1-3 52 Latch, Charging Handle 62289 Bi-4 52 Spring, Charging Handle Latch 61875 Bi-5a 52 Handguard Assembly RH 62198 BI-5b 52 Handguard Assembly LH 62196 FIGURE A13. BARREL REMOVAL VISE JAWS (P/N 62585) ee 3 Suppressor, Flash pea Bi-8 52 Replacement Barrel & Front Sight Assembly 62744 BI-9 52 Post, Front Sight 61706 61-10 52 Detent, Front Sight 61705 Bi-1 52 Spring, Front Sight Detent 61708 B1-12 52 Pin, Taper, Front Sight 62086 61-13 52 Swivel, Sling, Forward 62280 Bi-14 52 Rivet, Front Swivel 91208 81-15 52 Cap, Handguard 62087 B1-16 52 Pin, Roll, Gas Tube 95108 Bi? 62 Gas Tube Assembly 61645 B1-18 52 Snap Ring, Handguard 90403 Bi-19 52 Spring, Wald Assembly, Handguard Slip Ring 61962 B1-20 52 Nut, Barrel 61902 Bi-21 52 Slip Ring, Handguard 61901 Bi-22 52 Pin, Cover Hinge 61658 Bi-23. 52 Ring, Retaining, Ejection Port Cover 90402 B1-24 52 Spring, Ejection Port Cover 61518 B1-25. 52 Ejection Port Cover Assembly 62112 B1-26 52 Pin, Roll, Rear Sight Drum™ 95101 . B1-27 52 Drum, Windage 61703 B1-28 $2 Detent, Rear Sight 61755 81-29 52 Spring, Rear Sight Detent 61754 B1-30 52 Screw, Rear Sight Windage 61702 B1-31 52 Sight, Rear 61700 49APPENDIX B (CONT.) REPLACEMENT PARTS LIST (CONT) Figure No. Page Nomenclature B1-32 B1-33 Bi-34 81-35 B1-36 81-37 B1-38 B1-a9 B1-40 Bi-41 B1-42 B1-43 Bi-44 NOTE: 52 52 52 52 52 52 Se 52 52 52 52 52 52 UPPER RECEIVER GROUP Spring, Rear Sight Pin, Roll, Forward Assist Assembly Spring, Plunger Pin, Roll (Paw! Pivoty** Pawl, Forward Assist Betent, Paw! Spring, Detent, Forward Assist Plunger Assembly Receiver, Upper Spring, Cover Latch Latch, Cover Ring, Retaining Cap, Protective ** — Multiple use item. 51 Colt Manual No. CM102 App B ‘Colt Manual No. CM102 App B FIGURE B-1. UPPER RECEIVER GROUP. (SEE PAGES 60 & 61 FOR COMPONENT NOMENCLATURE)Colt Manual No. CM102 App B APPENDIX B (CONT) REPLACEMENT PARTS LIST (CONT) FigureNo. Page Nomenciature Be-1 B22 82-3 B2-4 B25 B26 “62-7 82-8 B2-9 82-10 82-11 B2-12 B2-19 82-14 “NOTE: P/N 62770 consists of P/N 62768, Insert Spring, and P/N 62769, FLLLL ELL LL ESET BOLT CARRIER GROUP Fin, Retaining, Firing Pit Pin, Firing : Pin, Cam Bolt Assembly Pin, Extractor Extractor Spring, Extractor Assembly Pin, Roll, Ejector Ejector Spring, Ejector and Safety Detent Fling, Balt Key & Bolt Carrier Assembly Screw, Cap, Hex Socket Head Kay, Bolt Carrier Spring Extracter. Both parts must be used as a unit. NOTE: "+ — Multiple use iter. Colt Manual No. C102 App. B PartNo. 62294 61704 62116 61563 61562 62770 95102 61564 61560" 61540 62286 e1sa7 FIGURE B-2. BOLT CARRIER GROUP (SEE PAGE 63 FOR COMPONENT NOMENCLATURE)Colt Manual No. OM102 App B Colt Manual No. CM102 App B APPENDIX B (CONT) REPLACEMENT PARTS LIST FigureNe. Page Nomenclature Part No. LOWER RECEIVER GROUP 83-1 56 Screw, Pistol Grip 92701 E 83-2 56 Washer, Lock 90001 5 B33 56 Grip, Pistol 62104 z Ba4 56 Spring, Ejector and Safety Detent 61569" BIS 56 Detent, Fira Control Selector 61785 38 Bo6 56 Spring, Detent, Takedown Pin 61692" eB 83-7 56 Detent, Takedown Pin 61698"* e = 83-8 56 Pin, Takedown 61655 a3 63-9 56 Butfer Assembly 62339 af B3-10 56 Spring, Action 61581 3 Ba11 56 Bultstock Stowage Assembly 62727 SE B312 56 Extension, Receiver ‘81574 gE Ba13 56 Screw Buttcap 92601 ai Ba14 56 'O' Ring Butistock 90218 ia 83-15 56 Retainer, Buffer 61582 = = 83-16 56 Spring, Buffer Retainer 61604 B3-17 56 Pin, Hammer and Trigger 61654** BS-18 56 Hammer & Hammer Pin Retaining Assembly 62317 B3-19 $6 Spring, Hammer 61697 B2-20 §6 Pin, Automatic Sear 61615 Ba21 56 Assembly, Automatic Sear 61622 B22 56 Selector, Fire Control 61959 Ba23 56 Disconnect 624 Bw-24 56 Trigger 61955 Ba-25. 56 Spring, Trigger 61857 63-26 56 Spring, Disconnect 61925 83-27 56 Pin, Roll, Bolt Catch 95105 B3-28 56 Catch, Bolt 62301 B3-29 56 Plunger, Bolt Catch ‘62178 q B3-30 56 Spring. Bolt Catch 62177 “| B3-31 66 Catch, Magazine 6166 j 2 B3-32 66 Button, Magazine Release 62032 B3-33 $6 Spring, Magazine Catch 61755 B34 §6 Pin, Roll, Trigger Guard 95101** B3-35 56 Trigger Guard Assembly 61970 B3-36 56 Pin, Receiver Pivot 62221 B3-37 56 © Spring, Trigger Guard 61531 63-38 56 Plunger, Trigger Guard 61250 83-39 56 Bushing, Automatic Sear 61609 NOTE; "= Multiple use item 55Colt Manual No. CM102 App 8 : Colt Manual Na, CM102 App B APPENDIX B (Cont) REPLACEMENT PARTS LIST Figura No. Page Nomenclature PartNo. 83-40 56 Spring, Automatic Sear 61616 3 2 B341 56 Pin, Roll, Tigger Guard Pivot Pin 95106 F Bo42 56 Buttstock B3-43 56 Buttplate Assembly Ba44 56 Door B-45 58 Plunger B3-46 56 Spring, Plunger 1 Ba47 56 Pin, Plunger Retainer Bo4s 58 Hinge Bo49 56 Pin Hinge B350 56 Screw BI-51 56 Swivel B4a-1 58 Sling, Silent B42 58 Loop, Sling Silent B43 38 Magazine Assembly—30 rounds 2 B44 58 Follower, Magazine, Plastic—30 rounds B45 38 = Spring, Magazine—30 rounds B46 58 Plate, Bottom, Magazine—30 rounds FIGURE B4—SLING SILENT ANC MAGAZINE {SEE PAGE 57 FOR COMPONENT NOMENCLATURE} 5?Colt Manual No. CM102 App & ‘Colt Manual No. CM102 App C ! fit APPENDIX C ‘ NUMERIC PARTS LIST M1641 RIFLE Part No. Part Name . No. Req'd. 50361 Spring, Detent, Forward Assist 1 61250 Plunger, Trigger Guard 1 61518 Spring, Ejection Port Cover 1 61531 Spring, Trigger Guard 1 61540 Ring, Bott a 61547 Kay, Bolt Carrier 1 61562 Extractor 1 61563 Pin, Extractor 1 61564 Ejector 1 61569 Spring, Ejector and Safaty Detent 2 e1574 Extension, Receiver 1 61581 Spring, Action 1 ‘61582 Retainer, Butfer 1 61601 Spring, Automatic Sear 1 61604 Catch, Magazine 1 61609 Bushing. Automatic Sear 1 61615 Pin, Automatic Sear 1 61616 Spring, Automatic Sear 1 61622 Assembly, Automatic Sear 1 61645 Gas Tube Assembly 1 61654 Pin, Hammer and Trigger 2 61655 Pin, Takedown 1 61657 Spring, Trigger 1 61658 Pin, Cover Hinge 1 61692 Spring, Detent Takedown Pin 2 61604 Spring, Butfer Retainer 1Part No. 61696 61697 61698 61700 61702 61703 61704 61705 61706 61708 61709 61754 81755 81759 81785 G1B75 S1nt 61902 61925 61955 61959 61962 61970 Colt Manual No. CM102 App C APPENDIX C (Cont) NUMERIC PARTS LIST (Cont) (M16A1 RIFLE Part Name Spring, Cover Latch ‘Spring, Hammer Detent, Takedown Pin Sight, Rear Screw, Rear Sight Windage Drum, Windage Pin, Gam Detent, Front Sight Post, Front Sight Spring, Rear Sight Spring, Front Sight Detent Spring, Rear Sight Detent Detent, Rear Sight Spring, Magazine Catch Detent, Fire Control Selector Spring, Charging Handle Latch Slip Ring, Handguard Nut, Barrel Spring Disconnect Trigger ‘Selector, Fire Control Spring Weld Assembly, Handguard Slip Ring Trigger Guard Assembly Button, Magazine Release Pin, Taper, Front Sight Cap, Handguard 61 = shea Conan anne sass ae seue§ Part No. 62112 2116 RERSES S82 33 22 REQEOSSS00088 Colt Manual No. CM102 App G APPENDIX C (Cont) NUMERIC PARTS LIST (Cont.) M16A1 RIFLE Part Name Ejection Port Cover Assembly Bolt Assembly Washer, Lock Spring, Bolt Catch Plunger, Bott Catch Grip, Pistol Handguard Assembly LH Handguard Assembly RH Key & Bolt Carrier Assembly Latch, Charging Handle Charging Handle Assembly Pin, Firing nj aaa eeeaafColt Manual No. CM102 App C Colt Manual No. CM102 App C APPENDIX C (Cont, APPENDIX C {Cont} q PARTS LIST (Cont, NUMERIC PARTS LIST (Cont) NUMERIC (com) MiGA1 RIFLE M16A1 RIFLE “ PartNo. Part Name No. Req'd Parte, Part Name No. Req'd. 62770 Spring Assembly, Extractor 1 62301 Catch, Bolt 1 90001 ‘Washer, Lock 1 62317 Hammer and Hammer Pin Retainer Assembly 1 90402 Ring, Retaining, Ejection Port Latch, Cover 1 Cover 1 Ring, Retaining 1 90403 Snap Ring, Handguard 1 62328 Magazine Assembly (30 Round) 1 91182 Can Prowetive As Required on Disconnect 1 91209 Rivet, Front Swivel 1 62335 Pin, Retaining, Firing Pin 1 92201 Screw, Cap, Hex Socket Head 2 e2339 Butter 1 92701 Screw. Pistol Grip 1 Suppressor, Flash 1 95101 Pin, Roll, Rear Sight, Drum and Follower, Magazina, Plastic (30 Round) 1 ‘Trigger Guard 2 Spring, Magazine (30 Round} 1 95102 Pin, Foil, Ejector and Plunger Retainer i 62868 Plata, Bottom, Magazine (30 Round) 1 95105 Pin, oil, Bolt Gatch 1 62727 Buttstock Siowage. 1 95106 Pin, loll, Trigger Guard Pivot Pin 1 62728 Butplate Assembly 1 95108 Pin, All, Gas Tube 1 62731 Plunger 1 95113 Pin, Roll, Latch or Pawl Pivot 2 62732 Spring, Plunger 1 95128 Pin, Roll, Forward Assist Assembly 1 62733 Door 1 62734 Pin Hinge 1 62735 Screw 1 62738 Hinge 1 62737 Swivel 1 62738 Butistock 1 Gzraq Replacement Barrel and Front Sight Assembly 1 84Cott Manual No, GM102 FIGURE C-1—ARMORER'S KIT PT. MO. 62575, | ' ; ‘COLT's ARMORER'S KIT CONTAINS THE NECESSARY TOOLS FOR INSPECTION, MAINTENANCE AND REPAIR OF THE Wiié & MIBAI AUTOMATIC RIFLE. THE KITIS: INTENDED FOR USE BY THE ARMORER AND DEPOT PERSONNEL. MAINTENANCE AND REPAIR ON THE MODEL M-3 BIPOD AND THE MODEL M-7 BAYONET CAN ALSO BE PERFORMED WITH THIS KIT Pane. emciplion Pete, amesiption 4 RIE When, Terma renga Ore 2 ae Game Pun joe Om PO 2 SA tec Rich ent 2 maim ene, Buren, [700m Pr} Baer pranen, arguing. 9° 59. Bret Amc Hr Sacha Seow ny. Schl Sow) 4 Sara Harner al Pan artists 2 eed Pact Pn ete reenter 5S ganas rarer. a Ber gerard ae 2P Whe, Pend ght Aung setae Sob Fen, Pant Tt = Dr 2 ara7 Somedhoe: Handl Far Blac, Mecha = oer Conon = 9 BHTSt Fes, Rnting ing. Ema a 1 werd Bet 2 15 AR Ye deme Bard erro a 2 om ma (Oban Fie 58 ae u TE 2M od ecdon Cleaneg 55H = 14 aaT Se Hodes Baca, Carag fn a ™ 12 rz _eprmany, Foe gp Dea m 1o SOT. ipengne, Bac Fn Dtet ™ Th peas sane wom Hes BOB a eH Bash Clery. Bowe 558 i MISE Pune Pa one a) w Ah RTE ead Senge Pt x = 65 : 2 NOTES