Senior Engineer - Fuel Systems

Key Responsibilities

• Lead the engineering, design and development of fuel systems across vehicle programmes.
• Own the development of fuel delivery systems, fuel tanks, evaporative emissions-compliant pipe and hose systems, carbon canisters and purge systems.
• Define system and component requirements, technical specifications and attribute summaries.
• Manage BoM structure, mass, design maturity and engineering release timing.
• Lead feasibility studies and risk assessments to inform design decisions and mitigate potential issues.
• Carry out FMEA from the earliest conceptual stages of design to identify and reduce potential failures.
• Develop DVP requirements from system attributes and FMEA outputs to ensure durability, reliability and functionality.
• Work closely with suppliers on design-for-manufacture studies to ensure components achieve programme requirements.
• Lead internal stakeholders and external partners in defining design requirements, specifications and programme deliverables.
• Manage the delivery of fuel system components and assemblies in line with programme timing.
• Create and maintain working-level engineering plans aligned with programme requirements.
• Ensure fuel systems are effectively integrated with the wider vehicle and powertrain systems.
• Work closely with design/styling, attributes, quality, development, purchasing and manufacturing teams.
• Build strong working relationships with suppliers and partners delivering black-box and grey-box systems.
• Consider performance, mass, certification/compliance, aesthetics and sustainability throughout system development.
• Provide technical expertise, guidance and mentorship to multidisciplinary engineering teams.
• Present relevant metrics and KPIs to the Principal Engineer / Function Group Lead and programme management.
• Propose continuous improvement initiatives across fuel system design processes, methodologies and tools.
• Review current design processes and create appropriate design and drawing standards for fuel system components.
• Support component R&D and future application of fuel system technologies across programmes.

Skills, Knowledge and Expertise

• 5–10 years' experience in the design and engineering of high-performance fuel systems.
• Bachelor's or Master's degree in mechanical, automotive, aerospace engineering or a similar discipline.
• Proven experience as a Senior Engineer, with a focus on leading design and project engineering.
• Strong knowledge of fuel system engineering, development and optimisation.
• Understanding of fuel flow system sizing.
• Experience with aluminium fabricated fuel tank design and manufacture.
• Strong knowledge of pipe and hose technology, with particular emphasis on joint design.
• Knowledge of evaporative emissions-compliant fuel system design for EU, CARB and EPA requirements.
• Understanding of Regulation (EU) 2018/858, US 40 CFR Part 86 and California CCR Title 13 regulations.
• Hands-on experience with fuel delivery system calibration strategies as required by EMS.
• Experience with emissions chassis dynamometer testing and evaporative SHED testing protocols.
• Experience with relevant engineering tools and software.
• Experience working with suppliers and external partners on component development and delivery.
• Strong leadership and interpersonal skills, with experience leading engineering teams.
• Ability to work independently on engineering and project management topics while operating effectively across multidisciplinary teams.
• Organised, persuasive, resourceful, flexible and self-directing, with a passion for delivering objectives.
• Comfortable challenging existing processes and developing improved engineering approaches.
• Clear and effective communication skills with internal and external stakeholders.
• A creative thinker with a passion for pushing the boundaries of engineering possibilities.
• A strong team player

• Establish strong team member relationships and provide technical support for development, coaching and mentoring.
• Manage day-to-day team activities within the programme and delegate workloads fairly.
• Plan and evaluate team activities and delegate as required.
• Support the Principal Engineer / Function Group Lead with resource requirements and justification.
• Work with the internal recruitment team when required.
• Lead by example.
• Manage conflict, resolve incidents and support effective problem solving.
• Share and cascade information and communicate programme goals clearly.
• Promote collaboration between engineers, SQE and purchasing.