The present investigation emphasis on characteristics of pyrolysis products was obtained by intermediate pyrolysis of Aegle marmelos (AM) deoiled seed cake and appropriateness of engine adaptation. The superior volatile matter (73.69%) contented AM biomass was elected as the feed stock in this study. Pyrolysis experiment was done by a fixed bed reactor at 600°C and obtained 42–55% bio‐oil yield. Investigation of bio‐oil by GC/MS and FTIR established the occurrence of methyl, ester, alkanes, ketones and oxygenated chemicals have been alternates for fossil fuels. SEM and EDX analysis of bio‐char exposes activated carbon and ensured that biochar can be used in the waste water treatment plant, solid fuel, organic fertilizer, and natural mosquito destroyer. According to GC analysis, the presence of CH4, H2, and C2H6 evolved syngas in AM pyrolysis process can be used C.I engines at dual fuel mode operation. An engine test reveals that adding of the pyrolysis oil diminished BTE (%) and increasing BSEC (MJ/kWhr). However, increasing bio‐oil ratio blend with diesel reduces hazardous emissions like CO, HC, NOx, and smoke in the exhaust. Based on engine results, it was proposed that equal to 20% of AM bio‐oil can be used as a fuel substitute for diesel engines. © 2018 American Institute of Chemical Engineers Environ Prog, 38:e13116, 2019