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Key Responsibilities and Required Skills for an Engine Tester | Powertrain Performance & Durability Specialist

💰 $55,000 - $95,000

EngineeringAutomotiveManufacturingQuality AssuranceTechnical Specialist

🎯 Role Definition

As an Engine Tester, you are the crucial link between design and reality. You will be entrusted with our state-of-the-art test cells, where you'll rig, run, and rigorously evaluate cutting-edge engine and powertrain systems. Your primary mission is to generate high-quality, repeatable data that drives engineering decisions, ensures product reliability, and guarantees compliance with global standards. This is a unique opportunity to apply your deep mechanical knowledge and technical skills to directly influence the performance and quality of future vehicles.

📈 Career Progression

Typical Career Path

Entry Point From:

  • Automotive Technician (Master or Certified)
  • Mechanical Engineering Technology Graduate
  • Powertrain Test Technician

Advancement To:

  • Senior Engine Tester / Lead Test Engineer
  • Test Cell or Lab Manager
  • Engine Calibration Engineer
  • Validation & Verification Engineer

Lateral Moves:

  • Field Service Engineer
  • Powertrain Quality Engineer
  • Data Analyst (Powertrain Performance)

Core Responsibilities

Primary Functions

  • Install, dress, and meticulously set up a diverse range of internal combustion engines and complete powertrain systems onto dynamometer test beds.
  • Instrument engines with a wide variety of sensors, including thermocouples, pressure transducers, accelerometers, and strain gauges, ensuring precise placement and data integrity.
  • Operate and configure sophisticated data acquisition (DAQ) systems and dynamometer control software (e.g., AVL PUMA, Horiba STARS, Froude Texcel).
  • Execute complex, pre-defined test cycles and durability schedules to evaluate engine performance, fuel economy, and emissions according to industry standards (SAE, EPA, EURO).
  • Vigilantly monitor critical engine parameters and test cell conditions in real-time, making decisive adjustments as necessary to maintain test integrity and safety.
  • Systematically diagnose and troubleshoot mechanical, electrical, and software issues related to the engine, test cell equipment, and instrumentation during active testing.
  • Perform routine and preventative maintenance on test cell equipment, dynamometers, and associated facility support systems to ensure maximum uptime and data accuracy.
  • Conduct detailed engine teardowns, component inspections, and failure analysis post-test to identify wear patterns, damage, and potential root causes for engineering review.
  • Compile, process, and perform initial analysis of complex test data using software tools like MATLAB, DIAdem, or advanced Excel to validate results and identify performance trends.
  • Author comprehensive and clear technical reports summarizing test procedures, key results, critical observations, and actionable recommendations for engineering and design teams.
  • Collaborate directly with design, calibration, and validation engineers to deeply understand test objectives and provide critical feedback on engine performance and behavior.
  • Manage the inventory and logistics of test engines, specialized components, and consumables required for daily testing operations and project timelines.
  • Uphold and enforce stringent safety protocols within the test cell environment, including the proper handling of fuels, fluids, and high-voltage systems (for hybrid powertrains).
  • Fabricate and modify test hardware, including custom brackets, exhaust plumbing, and fluid lines, to accommodate unique engine configurations and specific test requirements.
  • Calibrate sensors, instrumentation, and data acquisition channels according to a defined schedule to maintain ISO/IEC 17025 or other quality standard requirements.

Secondary Functions

  • Interface with CAN communication tools (e.g., Vector CANalyzer, PEAK-System) to monitor and log ECU data streams during test execution for deeper analysis.
  • Support the development and validation of new test procedures and automated scripts to improve testing efficiency, accuracy, and repeatability.
  • Maintain meticulous and detailed records of all test activities, engine build specifications, and hardware changes in a centralized database or logbook system.
  • Coordinate with internal and external labs for fluid analysis (oil, coolant, fuel) and material analysis to supplement test data and failure investigations.
  • Participate actively in design reviews and provide practical, hands-on feedback to development teams based on testing experience and direct observations.

Required Skills & Competencies

Hard Skills (Technical)

  • Dynamometer Operation: Proficiency in operating engine dynamometers (AC, DC, or eddy current) and their associated control systems like AVL PUMA or Horiba STARS.
  • Data Acquisition (DAQ): Hands-on experience with data acquisition hardware and software such as National Instruments (NI) LabVIEW/VeriStand, Dewesoft, or ETAS.
  • Engine Expertise: Strong mechanical aptitude and in-depth knowledge of internal combustion engine theory, operation, assembly, and failure modes.
  • Calibration & Diagnostic Tools: Experience with engine calibration tools (ETAS INCA, ATI Vision) and OEM diagnostic software.
  • CAN Bus Analysis: Solid understanding of CAN bus protocols and practical experience with analysis tools (e.g., CANalyzer, PCAN-View, Dearborn).
  • Technical Schematics: Ability to read and interpret complex mechanical drawings, electrical schematics, and Piping & Instrumentation Diagrams (P&IDs).
  • Data Analysis: Proficiency in using data analysis software such as MATLAB, UniPlot, DIAdem, or performing advanced functions in Microsoft Excel.
  • Mechanical Tooling: Highly skilled in using a wide range of mechanical hand tools, power tools, precision measuring instruments, and diagnostic equipment.
  • Fabrication: Basic fabrication skills (MIG/TIG welding, machining, tube bending) for creating custom test fixtures and fittings.
  • Emissions Systems: Knowledge of standard emissions testing equipment (5-gas analyzers, particulate matter counters) and related regulatory test procedures.

Soft Skills

  • Problem-Solving: Exceptional troubleshooting abilities with a logical, methodical approach to identifying the root cause of complex technical issues.
  • Attention to Detail: A meticulous nature to ensure utmost accuracy in instrumentation, test execution, data collection, and reporting.
  • Communication: Strong verbal and written communication skills for clearly reporting findings and collaborating effectively with cross-functional engineering teams.
  • Adaptability: Ability to thrive in a fast-paced, dynamic R&D environment where priorities and test plans can change rapidly.
  • Safety Mindset: A proactive and unwavering commitment to maintaining a safe, clean, and organized work environment.
  • Teamwork: A collaborative spirit with the ability to work effectively both independently and as a key member of a project team.

Education & Experience

Educational Background

Minimum Education:

  • Associate's Degree in Automotive Technology, Mechanical Engineering Technology, or a related technical field.
  • Equivalent demonstrated experience through military training or certified apprenticeship programs will also be considered.

Preferred Education:

  • Bachelor of Science in Mechanical Engineering, Automotive Engineering, or Electrical Engineering.

Relevant Fields of Study:

  • Automotive Technology
  • Mechanical Engineering
  • Powertrain Systems
  • Mechatronics Engineering

Experience Requirements

Typical Experience Range: 2-7 years of hands-on experience in an engine, powertrain, or vehicle testing environment.

Preferred: Direct experience with performance and durability testing of diesel, gasoline, or alternative fuel engines. Relevant ASE certifications (A1-A9) are a significant plus. Experience in an R&D or validation lab setting is highly desirable.

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