Senior Calibration Engineer (Livonia, MI or other unanticipated locations throughout the U.S.)

At Roush, we fuse technology and engineering to provide product development solutions to customers in a diverse range of industries. Widely recognized for providing engineering, testing, prototype, and manufacturing services to the transportation industry, Roush also provides significant support to the aerospace, defense and theme park industries. With over 2,400 employees in facilities throughout the United States, Europe, Asia, and South America, our unique combination of creativity and tenacity activates big ideas on a global stage.

Roush Power Systems manufactures and sells world-class power systems for the on-road and off-road market sectors focused on class 4-8 commercial vehicles, mobile off-road, and stationary off-road equipment. 

Responsibilities and duties for this role include: 

• Designing, calibrating, validating, and supporting powertrain and engine control systems to meet vehicle emissions, On Board Diagnostics (OBD) and regulatory requirements for OEM and commercial vehicle customers.
• Developing, updating, and validating engine and powertrain control module calibrations to meet emissions, diagnostic, and performance requirements across powertrain programs.
• Planning, coordinating, and executing powertrain calibration and validation testing using engine dynamometers, chassis dynamometers, test tracks, and public road environments, including evaluations in hot, cold, and high-altitude operating conditions to confirm calibration robustness and diagnostic readiness.
• Reviewing and interpreting control algorithms and software documentation, acquiring and analyzing test data using standard calibration and analysis tools, and recommending calibration or control strategy changes based on test results.
• Inducing diagnostic malfunctions and validating fault detection, monitoring logic, and OBD readiness behavior to ensure proper system operation.
• Supporting tailpipe emissions and OBD compliance activities in accordance with U.S. federal and state regulations, including CARB/ARB and EPA requirements, for gasoline and alternative fuel vehicles.
• Utilizing Original Equipment Manufacturer (OEM) software and control algorithms to develop calibrations in laboratory and on-road environments.
• Analyzing test results, developing and executing actions to provide solutions for issues.
• Conducting in-vehicle calibration evaluations and providing expert powertrain function assessments.
• Performing hot and cold climate and high-altitude development testing to meet product objectives.
• Providing positive technical contributions and guidance in a project team environment and mentoring less experienced engineers.
• Preparing and delivering technical reports and facilitating presentations to the group and customer management teams.
• Supporting the validation and release of the calibrations into production.
• Collaborating with cross functional engineering teams, test technicians, suppliers, and customers, and providing technical support during vehicle testing, corrective actions, field updates, and running changes as required.
• Providing Engine calibration and validation for OBD, emissions, fuel economy, and performance across internal combustion, hybrid, and alternative fuel powertrain systems.
• Developing and interpreting engine control algorithms using model-based methods with Simulink and embedded C software, recommending calibration and control strategy improvements based on test results.
• Performing test data acquisition, processing, and analysis using ETAS INCA/MDA, dSPACE CalDesk and ControlDesk, ATI Vision, AVL CRETA, GEM, and PUMA test systems.
• Performing calibration and validation testing across engine dynamometers, chassis dynamometers, test tracks, and public roads under extreme hot, cold, and high-altitude conditions.
• Ensuring OBD compliance in accordance with U.S. federal and state regulations (EPA, CARB/ARB), including Production Vehicle Evaluation (PVE) testing using OBD diagnostic tools.
• Conducting engine endurance, torque, and power performance testing.

Qualifications and Skills Required:

BA in Mechanical Engineering and 24 mon. exp. in any Calibration Engineer/Design Engineer position or related.

24 mon. skills/experience needed in: OBD calibration & validation updating ECM controls & software; Vehicle instrumentation; Chassis Dyno (AVL GEM) & gas Analyzer (HORIBA) operation; data collection using software - ETAS-INCA; DSPACE; ATI VISON; PCM ROM for engine/vehicle validations; AVL CRETA; ARAS Innovator; Engine Dyno endurance, performance & calibration testing with AVL PUMA tools.   

Work may occur from anywhere within the U.S.

Standard: 40 hrs/wk.  8:00 am – 5:00pm. 

Benefits and Perks:

Our full-time benefits include: medical, dental, vision, life insurance, earned sick time, STD, LTD, 401K, tuition reimbursement, paid vacation, paid holidays, and more.
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Roush is an EO employer – Veterans/Disabled and other protected categories

If you need a reasonable accommodation for our employment application process due to disability,

please contact Roush Talent Acquisition at 734-779-7087.

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