This study applies the 1.9 orthogonal array of the Taguchi method to find out the best hydrogen injection timing, hydrogen-energy-share ratio, and the percentage of exhaust gas circulation (EGR) in a single DI diesel engine. The injection timing is controlled by an electronic control unit (ECU) and the quantity of hydrogen is controlled by hydrogen flow controller. For various engine loads, the authors determine the optimal operating factors for low BSFC (brake specific fuel consumption), NOx, and smoke. Moreover, net heat-release rate involving variable specific heat ratio is computed from the experimental in-cylinder pressure. In-cylinder pressure, net heat-release rate, AIF ratios, COV (coefficient of variations) of IMEP (indicated mean effective pressure), NOx, and smoke using the optimum condition factors are compared with those by original baseline diesel engine. The predictions made using Taguchi's parameter design technique agreed with the confirmation results on 95% confidence interval. At 45% and 60% loads the optimum factor combination compared with the original baseline diesel engine reduces 14.52% for BSFC, 60.5% for NOx and for 42.28% smoke and improves combustion performance such as peak in-cylinder pressure and net heat-release rate. Adding hydrogen and EGR would not generate unstable combustion due to lower COV of IMEP. (C) 2012 Elsevier Ltd. All rights reserved.