Abstract Fossil fuel run diesel engines are being favored in light, medium and heavy duty applications as they exhibit higher fuel conversion efficiencies. Direct injection diesels are still facing challenges to obtain trade-off between oxides of nitrogen and particulate emissions. There are sophisticated strategies such as common rail direct injection, particulate filters with associated sensors and actuators but limited to expensive comfort vehicles. In the present experimental study, a mechanically operated simple component, variable timing fuel injection cam, is designed for a 510 cc automotive type naturally aspirated, water-cooled, direct injection diesel engine. Modifications in the fuel injection cam and gear train are carried out to suit the existing engine configuration. Variable speed tests are carried out for testing the efficacy of component on both engine and chassis dynamometers for performance and emissions. It is observed that the engine which is already retarded could further be retarded with variable timing fuel injection cam. Significant reductions in NO x and smoke emission levels are achieved. Combined effect of VIC with 7% EGR could reduce CO by about 88%, HC + NO x by 37% and PM emissions by 90%. The Engine incorporated with the designed component and EGR, successfully satisfied the existing emission norms with improved power and specific fuel consumption.