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Engine Controls Engineer IV

Generac · Waukesha, WI · Full time

Posted May 19, 2026 · We last checked this listing on Oct 6, 2026

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Likely interview questions for this role

Written from this job description, not a generic list. Each one notes what the interviewer is really checking.

About your past

Walk me through a time you developed or calibrated an engine control system from a blank sheet to production. What did the process look like end to end?

What they are checking: whether the candidate has actually driven a control system through the full development lifecycle, not just supported pieces of it

Describe a time you had to design or validate a throttle, mixer, fuel control, or ignition system component. What went wrong during testing, and how did you fix it?

What they are checking: depth of hands-on component-level experience versus purely systems-level or theoretical knowledge

Tell me about a project where you had to work closely with a contract manufacturer or internal manufacturing partner to make a design manufacturable. What friction came up?

What they are checking: real cross-functional collaboration experience with manufacturing, which the role leans on heavily

Tell me about a time you had to explain a complex simulation or test result to someone without an engineering background. How did you frame it?

What they are checking: the communication skill the posting flags as essential for presenting to mixed audiences

Tell me about a time a design change you pushed for was rejected or delayed by a schedule or cost constraint. What did you do next?

What they are checking: how the person handles the tension between engineering ideals and product development schedule and cost pressure

What would you do

Say you're calibrating spark timing and AFR on a gaseous fueled engine and you hit a wall where improving emissions is hurting durability. How do you work through that tradeoff?

What they are checking: ability to reason through the classic performance-emissions-durability triangle that defines this job

If you inherited a control system design mid-development from someone who left the company, with an unclear bill of materials and undocumented test data, what's your first move?

What they are checking: how the candidate handles ambiguity and picks up ownership of incomplete technical work

A junior engineer on your team keeps making the same mistake in interpreting AFR sweep data. How do you mentor them through it?

What they are checking: ability to mentor less experienced engineers, a stated responsibility of this level IV role

About the work

Tell me about your hands-on experience with ATI Vision. What kinds of calibration tasks have you done with it, and how deep did you go?

What they are checking: verifying real, specific proficiency with the named tool rather than surface familiarity

How do you approach a cost-benefit and reliability risk analysis when two engine control component designs both meet the performance spec but come in at different costs?

What they are checking: whether the candidate can actually run the tradeoff analysis called out in the job duties, not just cite the terms

Explain how you'd set up a test and data acquisition plan to validate a new ignition control strategy across a range of gaseous fuels.

What they are checking: practical grasp of test planning and data acquisition tools, not just engine theory

Do you have experience using MATLAB/Simulink or Python to modify or interact with embedded control software? Walk me through a specific example.

What they are checking: whether the preferred software skills are real and applied, not just listed on a resume

What's your understanding of how intake and exhaust system pressure affects engine control strategy, and can you give an example where you had to account for it?

What they are checking: depth of core internal combustion engine knowledge specific to the control systems this role owns

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The full job description

As published by Generac.

We believe power is a promise - a shared commitment to be there for others when it matters most. For more than 65 years, we've turned big ideas into solutions that help protect homes, strengthen businesses and build a more resilient, efficient, sustainable energy future. Ready to Power a Smarter World with us? The Engine Controls Engineer IV plays an important role in advancing the design and performance of internal combustion engines (ICE), through engine development, data-driven analysis, engine controls system development, and design of system components. This position leverages data analytics, ATI Vision, and data acquisition tools to optimize system behavior, improve engine control, improve product reliability, and increase engine performance across a range of gaseous fueled applications. Major Responsibilities: • Designs, validates, and brings new engine controls (throttles, mixers, fuel control, ignition systems) to market • Specifies precise new engine design requirements • Develops, tests, and integrates complex engine control components and evaluates overall effectiveness, cost (including cost/benefit analysis), reliability (risk analysis), and safety • Designs, develops, executes, and evaluates testing, product specifications, and process validation plans • Creates and reviews material part specifications and bills of materials • Collaborates with internal manufacturing partners, contract manufacturers, designers, and product specialists to optimize complex and advanced component and system designs for manufacturability • Supporting product development plans (schedule, product cost, meeting design inputs) • Acts as a resource to mentor and teach less experienced engineers • Travel to other Generac facilities as necessary • Other duties as assigned Minimum Qualifications: • Bachelor of Science Degree in Mechanical or Electrical Engineering or related discipline • 7+ years of relevant work experience Knowledge, Skills and Abilities: • Experience in automotive development and calibration, or a related engineering discipline. • Hands-on experience with engine and engine component development. • Experience in powertrain calibration software - ATI/CAN or similar. • Hands-on experience with ATI Vision as applied to engine control systems. • Extensive experience in new IC engine control system design and development. • Proficiency in developing internal combustion engines, including understanding of the effects of spark control, adjusting AFR for best performance and emissions, durability, control system components, intake/exhaust system pressure, and emissions testing • Develops, tests, and integrates complex system components and evaluates overall effectiveness, cost (including cost/benefit analysis), reliability (risk analysis), and safety • Designs, develops, executes, and evaluates testing, product specifications, and process validation plans • Ability to perform detail-oriented work with a high degree of accuracy on multiple projects • Expert with internal combustion engine performance development and specification • Strong analytical and problem-solving skills, with a deep understanding of internal combustion engine design, operation, and testing. • Strong written and verbal communication skills with the ability to clearly interpret and present complex simulation results to technical and non-technical audiences. • Collaborate with internal manufacturing partners, contract manufacturers, designers, and product specialists to optimize complex and advanced designs for performance. Preferred Qualifications: • Master’s degree in mechanical engineering, Aerospace Engineering, Computer Science, or a related field of study • Advanced hands-on experience in IC engines and engine system development • Advanced experience using ATI Vision in the use for calibration development for internal combustion engines • Advanced experience in applying MATLAB/Simulink and Python in internal combustion engine development • Comprehensive knowledge of internal combustion engines and effective engine test methods • Experience with MATLAB/Simulink, Python, Labview, Vision, Concerto or similar to modify embedded control software • Extensive experience with internal combustion engine performance development and specification • Understanding of thermodynamics and fluid dynamics. • Understanding of internal combustion engine thermodynamic cycles. • Demonstrated written communication and presentation skills • Previous experience with SAP or equivalent ERP • Ability to easily apply engineering knowledge and experience to improve products, services and processes • Ability to translate technical information to all audiences. • Substantial data analysis and control/diagnostic feature creation skills • Ample familiarity with systems engineering based problem solving • Proven ability to work well with others as part of a diverse global team Benefits: • We are an inclusive company that celebrates differences and keeps equity and respect at the forefront. • Competitive Benefits: Health, Dental, Vision, & 401k • 401 (k) retirement savings plans with company match • Medical support programs: Maternity, Diabetes, Treatment Decision Support and more • Work-life benefits: PTO and Holidays Physical Demands: While performing the duties of this job, the employee is regularly required to talk and hear; and use hands to manipulate objects or controls. The employee is regularly required to stand and walk. On occasion, the incumbent may be required to stoop, bend, or reach above the shoulders. The employee must occasionally lift up to 25 pounds. Specific conditions of this job are typical of frequent and continuous computer-based work requiring periods of sitting, close vision, and the ability to adjust focus. Occasional travel. “We are an equal opportunity employer and all qualified applicants will receive consideration for employment without regard to race, color, religion, sex, sexual orientation, national origin, disability status, protected veteran status, or any other characteristic protected by law.”

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