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Diesel engines are one of the primary mode of power generation in India due to its higher thermal efficiency and greater torque. In one hand, the demand for higher brake horse power genset is growing in India and the other hand, the stringent engine emission norms are going to be imposed to control the air pollution. In present scenario, the major challenges countered by the automobile industries are to design the engines which meet the norms along with high load capacity with least modifications in existing design. Optimization of various parameters is considered as a viable solution. Full factorial experimental study (large numbers of experiments) is required to be carried out to evaluate the effects of all the parameters on performance and emissions of the engine which is time consuming as well as expensive.