Harness Design & Build Technician

About the Role

We are looking for a hands-on professional to prototype, test, and standardize wiring harnesses for FuelTech applications in cars, motorcycles, jet skis, trucks, and custom projects. The focus is on transforming application requirements into functional prototypes, with documentation and quality standards that enable production and support.

Responsibilities

Prototyping & Applied Engineering

• Prototype Plug and Play, universal, adapter, and unterminated wiring harnesses for multiple engines/platforms.
• Interpret pinouts, electrical diagrams, technical manuals, and integration requirements (ECU/VCU, CAN, sensors, and actuators).
• Define wiring harness electrical architecture: power/ground strategy, fuses/relays, protection, routing, and mounting.
• Design and assemble sub-harnesses (e.g., CAN, wideband, EGT, auxiliary modules) and integrate them into the main assembly.
• Select and specify components: connectors/terminals/seals, wire gauges (AWG), sleeves/loom, heatshrink/boots, etc.

Validation & Testing

• Perform bench tests and validation: continuity, short-to-ground, insulation resistance, voltage drop, and functional tests with ECU/actuators.
• Diagnose electrical/intermittent faults and propose design and process corrections.
• Define validation criteria and inspection checklists per product (e.g., CAN, VR/Hall, injectors/coils).

Documentation & Standardization (Prototype to Product)

• Create and maintain technical documentation: diagrams, bill of materials (BOM), assembly instructions (build rules), connector maps, versions/revisions.
• Support the transition to production: standardize lengths, breakouts, labeling/identification, and final testing.
• Work with purchasing/vendors to source components and approved alternatives.

Cross-Functional Interface & Inventory Control

• Collaborate with Product, Engineering, Support, and Sales teams to understand real needs and reduce rework.
• Provide technical support to the team regarding application questions, assembly, and troubleshooting.
• Manage supply inventory and order replenishment to ensure readiness at all times.

Technical Requirements (Essential)

• Hands-on experience in assembly/development of automotive/powersports wiring harnesses (OEM, aftermarket, or motorsport).
• Proficiency in professional crimping (various terminals), cable preparation, splices, and mechanical protection.
• Ability to read electrical diagrams and pinouts.
• Sensor integration experience (0–5V, NTC, VR/Hall) and actuators (injectors, coils, solenoids).
• Solid understanding of CAN bus (topology, termination, best practices).
• Proficiency with tools: crimp pliers, wire strippers, insertion/extraction tools, rework station (when applicable), multimeter, power supply, etc.
• Technical documentation organization and revision control.

Nice-to-Have (Preferred)

• Experience with common connectors and standards: Deutsch (DT/DTM), Weather Pack, TE/AMP (CPC/AMPSEAL), EV1/EV6, etc.
• Experience with race/milspec materials (ETFE/Tefzel, DR-25, boots, backshells) and/or high-performance sealed harnesses.

Behavioral Profile

• Meticulous attention to detail and process discipline.
• Diagnostic reasoning and analytical thinking.
• Product-oriented mindset.
• Clear and effective communication.
• Autonomy with accountability.
• Team collaboration.