The Senior Calibration Technician – Boost Control Systems is a technical leader responsible for the calibration, optimization, and validation of turbocharger boost control systems across advanced engine platforms. This role involves hands-on work with engine control units (ECUs), electronic actuators, pressure sensors, and real-time calibration tools to fine-tune wastegate, VGT, and e-boost systems for performance, emissions, and drivability targets. The senior technician supports R&D, leads test execution, and provides mentorship to junior team members while contributing to continuous improvement in calibration methodologies and system development.
Key Responsibilities:
Lead calibration of boost control strategies using ETAS INCA, ATI VISION, or equivalent tools, including PID tuning and actuator profiling.
Calibrate wastegate, variable geometry turbo (VGT), and electric boost actuators to achieve optimal transient response and target boost profiles.
Execute test plans across a full range of operating conditions (altitude, load, speed, ambient) in dyno and on-vehicle environments.
Define and execute calibration test plans for new engine programs, ECU releases, and emissions compliance validation.
Analyze time-aligned datasets from dyno/vehicle tests to evaluate boost pressure control, turbo lag, oscillation, and efficiency.
Provide root cause analysis for boost control issues and propose effective calibration or hardware countermeasures.
Oversee installation, setup, and calibration of sensors (MAP, MAF, EBP), actuators, and control modules for accurate data acquisition.
Troubleshoot complex issues related to control strategy, sensor drift, actuator fault codes, or unexpected boost behavior.
Work cross-functionally with controls, mechanical, and test teams to refine control logic and verify system robustness.
Mentor and guide junior calibration technicians in calibration tools, safety procedures, and data interpretation.
Lead continuous improvement of test processes, documentation, and standard operating procedures (SOPs).
Maintain detailed calibration records, change logs, and system configurations for traceability and compliance.
Key Focus Areas:
Leadership in calibration of turbocharger boost control systems
Expert-level tuning of wastegate, VGT, and electronic actuators
Data-driven optimization of PID and boost control maps
Cross-functional troubleshooting of hardware/software integration issues
Execution of validation and emissions compliance test plans
Mentorship of junior staff and development of test procedures
Boost system readiness for SOP, production, or performance targets
Qualifications & Skills:
Education:
Associate or Bachelor’s degree in Automotive Engineering, Mechanical Engineering, Mechatronics, or a related field required
Advanced technical certifications or OEM calibration training a plus
Experience:
5–8+ years of experience in engine calibration, dyno testing, or powertrain development
Demonstrated expertise in turbo system behavior, control strategies, and emissions-related tuning
Experience leading calibration activities across multiple platforms or development phases
Technical Skills:
Advanced proficiency in calibration tools (ETAS INCA, ATI VISION, Motec, or OEM-specific software)
Strong knowledge of engine management systems, ECU parameters, and boost control loops
Deep understanding of VGT and e-boost actuator control, PID behavior, and sensor diagnostics
Skilled in datalogging, post-analysis, and troubleshooting using CAN tools, oscilloscopes, and DVOMs
Soft Skills:
Strong leadership, problem-solving, and decision-making abilities
Excellent communication and documentation skills
Ability to prioritize tasks, lead projects, and coordinate with engineers and managers
Comfortable working in dynamic test environments under tight development timelines