Fuel System Design Engineer – High-Performance Automotive

Expleo Group

. Design and develop complete fuel system architectures and associated components for high-performance vehicle applications .

Posted 5/15/2026full-timeGuildford • 🇬🇧 United KingdomMid-LevelSeniorWebsite

Tech Stack

Tools & technologies

Assembly

About the role

Key responsibilities & impact

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, 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
Develop component and system-level validation plans and support execution of testing activities
Produce and maintain engineering documentation including CAD data, BOM structures, engineering release documentation, technical specifications, change requests, and issue tracking
Collaborate with vehicle integration teams, manufacturing teams, suppliers, and external partners, and participate in design reviews

Requirements

What you’ll need

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 associated components
Strong understanding of fluid systems, fuel routing and packaging, EVAP systems, pumps, valves, and filtration systems
Proficiency in CAD software such as CATIA V5 or equivalent 3D CAD platforms
Experience producing detailed component and assembly models, manufacturing drawings, GD&T-compliant engineering documentation
Experience using engineering analysis and modelling tools such as ANSYS, Mathcad, CFD / FEA software
Strong understanding of DFM (Design for Manufacture), DFMEA, engineering release processes, BOM management, product development lifecycle activities
Strong communication and collaboration skills
Proven experience in fuel system design within automotive, motorsport, aerospace, commercial vehicle, or other high-performance engineering sectors
Experience developing mechanical and fluid systems from concept through to production release
Hands-on experience working with manufacturing, suppliers, and test teams
Experience managing engineering changes and technical issue resolution throughout programme delivery
Exposure to high-performance or low-volume vehicle development environments is advantageous

Benefits

Comp & perks

Collaborative working environment
Expleo Academy - enables you to acquire and develop the right skills
Competitive company benefits
We stand shoulder to shoulder with our clients and peers through good times and challenges
We empower all passionate technology loving professionals by allowing them to expand their skills and take part in inspiring projects

ATS Keywords

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Applicant Tracking System Keywords

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Hard Skills & Tools

fuel system architecture3D CAD modelingfluid system analysisCFD toolsFEA methodsengineering calculationsGD&TDFMDFMEABOM management

Soft Skills

communication skillscollaboration skills

Certifications

Bachelor’s degree in Mechanical EngineeringMaster’s degree in Mechanical EngineeringBachelor’s degree in Automotive EngineeringMaster’s degree in Automotive EngineeringBachelor’s degree in MechatronicsMaster’s degree in Mechatronics