Injector remanufacturing

A method of remanufacturing a fuel injector,

• a. the fuel injector having an original lead extending out of an overmold block, the original lead having:
• (1) an embedded portion positioned within the overmold block, wherein the embedded portion includes a linear segment,
• i. the linear segment extending along a lead axis,
• ii. the lead axis being parallel with a long axis of the overmold block;
• and
• (2) a protruding portion positioned outside the overmold block;
• b. the method including the steps of:
• (1) milling a cavity into the overmold block using a milling cutter to cut into the overmold block an angle of at least several degrees with respect to an axis that is perpendicular to the long axis of the overmold block;
• (2) splitting the original lead into an original lead remainder portion and an original lead discard portion, the original lead remainder portion remaining within the overmold block;
• (3) removing the original lead discard portion from the overmold block;
• and
• (4) securing a replacement lead to the original lead remainder portion within the overmold block.

A method of remanufacturing a fuel injector,

• a. the fuel injector having an original lead extending out of an overmold block, the original lead having:
• (1) an embedded portion positioned within the overmold block;
• and
• (2) a protruding portion positioned outside the overmold block;
• b. the method including the steps of:
• (1) milling a cavity into the overmold block using a milling cutter to cut into the overmold block in a first direction;
• (2) splitting the original lead into an original lead remainder portion terminating in a remainder tip and an original lead discard portion, the original lead remainder portion remaining within the overmold block;
• (3) removing the original lead discard portion from the overmold block;
• and
• (4) securing a replacement lead to the original lead remainder portion within the overmold block,
• wherein the milling cutter, when cutting into the overmold block in the first direction to mill the cavity into the overmold block, cuts into the embedded portion of the original lead such that the remainder tip is angled.

A method of remanufacturing a fuel injector,

• a. the fuel injector having an original lead extending out of an overmold block, the original lead having:
• i. an embedded portion positioned within the overmold block;
• and
• ii. a protruding portion positioned outside the overmold block;
• b. the method including the steps of:
• i. milling a cavity into the overmold block using a milling cutter to mill into the overmold block, wherein the overmold block is milled in more than one direction;
• ii. splitting the original lead into an original lead remainder portion and an original lead discard portion, the original lead remainder portion remaining within the overmold block;
• iii. removing the original lead discard portion from the overmold block;
• and
• iv. securing a replacement lead to the original lead remainder portion within the overmold block.

A method of remanufacturing a fuel injector,

• a. the fuel injector including an original lead extending from an overmold block, wherein:
• i. the overmold block includes a milling surface, the milling surface having a milling surface normal that is perpendicular to a plane of the milling surface;
• and
• ii. the original lead includes an embedded portion positioned within the overmold block, and a protruding portion that protrudes from the overmold block through a lead aperture;
• b. the method including the steps of:
• i. milling a cavity into the overmold block using a milling cutter, wherein:
• 1) the milling cutter cuts into the overmold block in a first direction that makes an angle of at least several degrees with the normal of the milling surface;
• and
• 2) the milling cutter at least substantially severs the embedded segment of the original lead into a discard portion and a remainder portion;
• ii. removing the discard portion of the original lead from the overmold block;
• iii. inserting a replacement lead into the overmold block through the lead aperture such that the replacement lead overlaps the remainder portion of the original lead;
• and
• iv. securing the replacement lead to the remainder portion.