This work summarizes the modified thermal barrier coating and porous medium diesel engine characteristics under different loading conditions to evaluate cylinder pressure, brake thermal efficiency and emissions. Results show that the thermal efficiency of the modified engine at full load is increased by 6% than base engine. An increase in oxides of nitrogen emission by 3% was recorded for a thermal barrier coating engine while unburned hydrocarbons decreased by 38% and carbon monoxide decreased by 14%. Conversely, oxides of nitrogen emissions decreased by 63% due to the heat recuperation ability of the porous medium engine. Exergy analysis is carried out to predict the sources of energy destruction to improve efficiency.