Product Development Engineer - Propulsion/Body Exterior & Fuel Systems

Ford • Dearborn, MI

9d • $65,100 - $166,200 • Hybrid

About The Position

Ford Motor Company is seeking a highly motivated Fuel System Application Design & Release Engineer to join our Propulsion/Body Exterior & Fuel Systems engineering team. This role is responsible for the design, development, validation, and release of fuel system components and subsystems for current and future vehicle programs. The engineer will collaborate cross-functionally with manufacturing, purchasing, quality, and supplier partners to ensure fuel system designs meet performance, safety, regulatory, durability, and cost targets while supporting Ford's commitment to quality and innovation. This position requires a strong foundation in mechanical/automotive engineering, hands-on problem solving, and the ability to manage multiple priorities in a fast-paced, deadline-driven environment.

Requirements

• Bachelors in engineering
• At least 2 years of design and release experience.
• Proficiency in the usage of D&R tools such as WERS, Teamcenter, FEDE, Global 8D, DFMEA, DVP&R, APQP Reviews, and AIMs
• Self-starter with excellent communication and organization skills who can look ahead for the GPDS program deliverables, develop a workplan and drive the process both inside of Ford and with the supply base to meet the deliverables
• Working knowledge of GD&T, tolerance analysis, and DFMEA processes.
• Familiarity with automotive regulatory standards related to fuel systems and emissions (FMVSS 301, EPA/CARB evaporative emissions regulations).
• Strong analytical and problem-solving skills with the ability to interpret test data and drive engineering decisions.

Nice To Haves

• Previous Fuel Systems and launch experience is desired
• Master's degree in engineering.
• Excellent communication skills and ability to work effectively in cross-functional, global teams.
• Ability to travel occasionally to supplier sites, proving grounds, and manufacturing plants.

Responsibilities

• Design, develop, and release fuel system components (fuel tanks, filler pipes, fuel pumps, vapor management/EVAP systems, lines, and connectors) for passenger vehicles and trucks.
• Create and maintain CAD models, drawings, and engineering specifications using tools in Ford's PLM systems (e.g, TeamCenter, 3DX).
• Complete Fuel TechClub assessments at all program milestones
• Ensure fuel system designs comply with federal, state, and international regulatory requirements (FMVSS, EPA, CARB, ECE) related to evaporative emissions, crashworthiness, and fuel system integrity.
• Conduct design analysis including DFMEA, tolerance stacking, packaging studies, and structural/thermal simulations in coordination with CAE teams.
• Lead and support design verification and validation testing, including vehicle-level crash testing, durability testing, and evaporative emissions testing; analyze results and drive corrective actions.
• Manage the Engineering Change Level (ECL) process and Bill of Materials (BOM) accuracy throughout the vehicle program lifecycle.
• Collaborate with suppliers on component design, sourcing, and manufacturing feasibility; participate in supplier technical reviews and issue resolution.
• Partner with manufacturing and plant teams to resolve build issues, launch-related concerns, and continuous improvement initiatives.
• Support cost reduction initiatives and value engineering activities without compromising safety or performance.
• Participate in cross-functional Program Milestone reviews (e.g., PD milestones, Gateway reviews) and ensure timely completion of deliverables.
• Investigate and resolve field/warranty issues related to fuel systems using root cause analysis methodologies (8D, 5-Why, Fishbone).
• Ensure compliance with Ford's engineering standards, corporate design rules, and safety/regulatory documentation requirements.

Benefits

• Immediate medical, dental, vision and prescription drug coverage
• Flexible family care days, paid parental leave, new parent ramp-up programs, subsidized back-up child care and more
• Family building benefits including adoption and surrogacy expense reimbursement, fertility treatments, and more
• Vehicle discount program for employees and family members and management leases
• Tuition assistance
• Established and active employee resource groups
• Paid time off for individual and team community service
• A generous schedule of paid holidays, including the week between Christmas and New Year’s Day
• Paid time off and the option to purchase additional vacation time.

What This Job Offers

• Job Type: Full-time
• Career Level: Mid Level