Fuel System Design Engineer Automotive

Overview

Expleois a trusted partner for end-to-end, integrated engineering, quality services and management consulting for digital transformation. We help businesses harness unrelenting technological change to successfully deliver innovations that will help them gain a competitive advantage and improve the everyday lives of people around the globe.

An exciting opportunity has arisen for a Fuel System Design Engineer to join a high-performance automotive engineering environment, supporting the design, development, integration, and validation of advanced fuel system architectures for next-generation vehicle programmes.

This role will focus on the end-to-end development of fuel system components and assemblies, from concept definition through to prototype, validation, and production release. The successful candidate will work across multidisciplinary engineering teams to deliver high-quality, manufacturable fuel system solutions that meet demanding performance, packaging, durability, regulatory, and timing targets.

The position requires strong mechanical design capability, hands‑on engineering understanding, and experience working with fluid systems in high-performance automotive or related engineering sectors.

• Design and develop complete fuel system architectures and associated components for high-performance vehicle applications.
• Lead or support development of:
• Fuel tank assemblies
• Fuel filler systems
• Fuel pumps and filtration systems
• Fuel lines, manifolds, and sensors
• EVAP systems and charcoal canister integration
• Fuel retention and mounting systems
• Fuel metering and control components
• Develop detailed 3D CAD models, assemblies, and engineering drawings for fuel system components and installations.
• Perform vehicle integration and packaging studies to ensure compatibility with overall vehicle architecture and packaging constraints.
• Support concept generation and evaluation for new fuel system technologies and layouts.

• Use engineering calculations, modelling tools, and simulation methods to size and optimise fuel systems and fluid control components.
• Conduct fluid system analysis using:
• CFD tools
• FEA methods
• Thermal and flow simulations
• Evaluate system performance, durability, manufacturability, and reliability.
• Support tolerance analysis, stack-up assessments, and DFMEA activities.

• Develop component and system-level validation plans and support execution of testing activities.
• Support in‑house prototype builds and vehicle integration activities.
• Collaborate with test and validation teams on:
• Rig testing
• Pressure and leak testing
• Environmental and durability testing
• System verification and issue resolution
• Support development of bespoke test equipment and validation methodologies where required.

• Produce and maintain engineering documentation including:
• CAD data (2D & 3D)
• BOM structures
• Engineering release documentation
• Technical specifications
• Change requests and issue tracking
• Support engineering release processes ensuring designs meet internal standards, gateway deliverables, and regulatory requirements.
• Ensure CAD and engineering data are fully production‑ready and compliant with DFM principles.
• Support BOM management, engineering change processes, and configuration tracking throughout programme lifecycle.

• Work closely with:
• Vehicle integration teams
• Manufacturing and prototype build teams
• Suppliers and external partners
• Test and validation engineers
• Purchasing and programme management teams
• Participate in design reviews and technical discussions to ensure robust and optimised engineering solutions.
• Support supplier management activities, including technical reviews and component development coordination.

• Bachelor’s or Master’s degree in Mechanical Engineering, Automotive Engineering, Mechatronics, or a related engineering discipline
  .
• Strong understanding of mechanical systems and fluid system engineering principles.

• Proven experience designing and developing automotive or high-performance fuel systems and…