Nowadays, the use of biodiesel for diesel engines has been attracting researchers aiming to improve engine characteristics although the engine performance could be decreased while utilizing biodiesel. In this aspect, optimizing the piston bowl geometry is one of the useful approaches to enhance the efficiency of the biodiesel-powered diesel engine. In this study, the standard piston of an existing diesel engine was modified into two different combustion bowls, namely Symmetrical Stepped Curved-V (SSCV) and Symmetrical Spline-V (SSV), to evaluate the CI engine performance powered with mixtures of sesame-originated biodiesel, diesel fuel, and tert-butyl hydroquinone (TBHQ) additive through two-stage experiment. In the first phase, experiments were carried out on two modified piston bowls powered by diesel and S20 (20% sesame biodiesel + 80% diesel fuel). Resultantly, SSV piston revealed superior engine characteristics to SSCV piston and standard piston due to enhanced air–fuel mixing and more complete combustion of SSV piston-based engine. Indeed, SSV piston operation exhibited an 8.68% of increased brake thermal efficiency (BTE), 6.54% of curtailed brake-specific fuel consumption (BSFC), 4.76% of lowered carbon monoxide (CO), 4.84% of decreased unburnt hydrocarbon (HC), and 2.22% of lowered smoke opacity but with increased nitrogen oxide (NOx) by 14.14% in comparison to diesel. In the 2nd phase, to control the NOx emission effectively, a TBHQ additive was added to the S20 sample at different proportions (500 mg and 1000 mg) to analyze the test engine behaviors with modified piston shapes. As a result, S20 + 500 mg TBHQ at 100% load improved BTE by 5.79% and reduced BSFC by 4.36% in the case of SSV piston. Moreover, it curtailed emissions of CO, HC, NOx, and smoke opacity by 13.33%, 15.49%, 12.09%, and 9.44%, respectively, when equated with diesel. Overall, S20 + 500 mg TBHQ could be thought of as a possible alternative fuel on SSV piston as it resulted in superior performance and emission characteristics in the existing standard engine. The current study's findings could pave the way for the development of diesel engines with modified piston geometry that is more efficiently compatible with biodiesel blends and additives.