In this present world, the realization of the available of fossil fuels [diesel] is limited and hence it is necessary for the efficient use of the fuel. The increasingly environmental regulations also make it necessary to improve the functioning of the diesel engine in terms of their durability and efficiency. Thus, there is a high scope in engine technology to increase the engine ratings and reduce fuel consumption. For this purpose, the Thermal Barrier Coating (TBC) has been extensively used in engine technology. The T.B.C technology has been applied on some parts of Diesel engine (piston crown and cylinder head) Plasma Spray technique was used for spraying process. The piston crown and Cylinder head of the diesel engine were coated for a thickness of 0.25mm. Callophyllum oil was converted into biodiesel by two stage Transesterification process using NaOH as a catalyst. Several tests have been carried out to examine properties, performance and emission characteristics for different blends such as [B100, B20, B30, B40 and B100] in comparison with pure diesel for varying injection pressures like 160 bar, 180 bar and 200 bar pressure. These tests were conducted on a single cylinder, 4 stroke, water cooled, direct injection computerized compression ignition engine.