In these times of efforts to develop high-efficiency hydrogen-adopted or hydrogen-fueled internal combustion engines (ICEs), and concerns related to electric vehicles such as battery cost, drawbacks in harsh winter climates, low range, etc., it is important to generate original ideas in line with the manufacturing of ICEs with improved efficacy. Accordingly, this study presents a comprehensive experimental investigation to observe the cooperated effects of pulse width modulation (PWM)-controlled hydroxy (HHO) gas introduction and improvement in tribological performance of piston ring-cylinder liner mechanism on performance and emission characteristics of a spark-ignition (SI) engine (co-system). The variation of compression ratio (CR), influence of two electrolyzer types of tube electrolyzer (TE) and plate electrolyzer (PE) for production of HHO gas, and zeta potential (ZP)-based dynamic light scattering (DLS) analysis to specify the optimal catalyst concentration in de-ionized water were also observed. Electron cyclotron resonance-chemical vapor deposition (ECR-CVD) method was utilized to bombard the piston ring substrates with diamond-like carbon (DLC) atoms under high energy plasma to improve the mechanical strength of the friction surface. Using linear tribometer, the uncoated (UPR) and coated piston rings (CPR) underwent friction tests to determine the wear rate (WR), and coefficient of friction (COF) which have substantial contribution to frictional losses. The surfaces of the samples were visualized via scanning electron microscopy (SEM) and atomic force microscopy (AFM) before and after abrasion tests to analyze carbon coating and its effects on tribological performance. The observations depicted that HHO flowrate needs to be varied as the engine load and CR change, and based on these observations, PWM control unit was designed, manufactured and reprogrammed so as to adjust electrical power consumption of HHO system when needed. The aforementioned analyses ensured optimization of the overall system so as to maximize the efficiency of the test engine. The co-system with optimized parameters (CPR + HHO + PWM) yielded an increase in average brake power (Pe) up to 31%, and average reductions in specific fuel consumption (β), carbon monoxide (CO), unburned hydrocarbon (UHC), and nitrogen oxide (NOx) emissions by 17%, 25%, 19%, and 14%, respectively at engine load range from 20% to 100%. It is expected that this study will be a good guide in terms of developing high-efficient ICEs due to promising results provided by the co-system. •Electrolyzers.•KOH catalyst.•HHO flow control.•Variable compression ratio.•Tribology.