The engine of your aircraft has been running great for years. But now you're getting close to that 2,000-hour mark. Or maybe you've noticed it's using more oil than it used to. Either way, you're starting to think about the big one: an engine overhaul.

If you own an airplane with a Lycoming IO-series engine, you're in good company. These engines power some of the most popular planes in general aviation. The IO-360 runs in the Cessna 172, Piper Arrow, and Grumman Tiger. The IO-540 powers the Piper Cherokee Six and Cessna 206. 

The smaller IO-320 is found in trainers and light singles. All of these are part of the same proven engine family. The IO-Series engine family was first certified back in 1955, and since then it's been installed in thousands of aircraft. That's nearly 70 years of proven performance. It's known for being tough and reliable. But even the best engines need a refresh eventually.

Here's the hard truth. The overhaul cost for these engines has gone up a lot in recent years. We're talking about a big investment. Depending on your choices, you could spend anywhere from $28,000 to over $85,000. That's a wide range, and a lot of factors affect where you'll land.

The good news? You have options. You can go with a factory overhaul or choose an independent shop. You can pick new parts or overhauled ones. You can even fly past the recommended time if your engine is healthy. Understanding these choices helps you plan better and maybe even save some money.

This post explains what you'll actually pay and what affects your final bill.

Key Takeaways

How much does an IO-Series overhaul cost? A Lycoming IO-series overhaul typically costs between $28,000 and $75,000 for the engine work alone, depending on the engine model. Four-cylinder engines like the IO-320 and IO-360 fall on the lower end. Six-cylinder engines like the IO-540 cost more due to additional parts and labor. Factory rebuilds run about $64,000 to $75,000 plus a core charge, while independent shops charge $32,000 to $65,000. Add another $5,000 to $10,000 for removal, reinstallation, propeller work, and accessories. Your total "all-in" cost will likely fall between $38,000 and $85,000 depending on your choices.

OptionIO-320/IO-360 CostIO-540 CostTotal Estimated Cost
Factory Rebuild$64,000 + core$75,000 + core$70,000 - $85,000
Factory Overhaul$58,000 + core$68,000 + core$65,000 - $80,000
Major Shop Overhaul$33,000 - $53,000$45,000 - $65,000$40,000 - $75,000
Local Shop Overhaul$32,000 - $41,000$40,000 - $55,000$38,000 - $65,000
IRAN (Inspect/Repair)$20,000 - $25,000$25,000 - $32,000$28,000 - $42,000

What Is an Engine Overhaul?

Think of an engine overhaul like a complete rebuild of your car's motor. The mechanic takes the whole thing apart, piece by piece. They clean everything. They inspect every part. Then they replace anything that's worn out. Finally, they put it all back together and test it.

For your O-360 or IO-360, this process follows strict rules set by the manufacturer. The engine shop will:

What Parts Get Replaced?

During a typical overhaul, several key components almost always get replaced. The cylinder assemblies usually get new or rebuilt units. The camshaft often needs replacing because it wears down over time. The crankshaft gets inspected and sometimes reground to bring it back to spec.

Here's a general list of what gets attention:

Why Do Engines Need Overhauls?

Every time your engine runs, metal parts rub against each other. Even with good oil, this causes tiny amounts of wear. Over thousands of hours, that wear adds up. Tolerances that were once tight become loose. Compression drops. Performance suffers.

An overhaul brings everything back to like-new condition. It restores the power your engine made when it was fresh. More importantly, it keeps you safe. A well-maintained engine is far less likely to have problems in flight.

The process also lets mechanics find hidden issues. A crack in the crankcase. A worn bearing about to fail. Corrosion starting on internal parts. Catching these problems during an overhaul prevents them from becoming emergencies later.

An engine overhaul is a major event in your airplane's life. It's expensive and time-consuming. But it's also an investment in safety and performance. A properly overhauled IO-series engine can run another 2,000 hours or more. That's potentially another 10 to 20 years of reliable flying, depending on how much you use the plane.

When Does Your IO-Series Engine Need an Overhaul?

The short answer? When the manufacturer recommends it, or when your engine tells you it needs one. Let's look at both.

The Official Recommendation

Lycoming sets what's called a TBO, which stands for Time Between Overhaul. For most IO-series engines, the TBO is 2,000 hours or 12 years. Some models vary slightly. The IO-320 and IO-360 share this 2,000-hour recommendation. The IO-540 also carries a 2,000-hour TBO in most configurations. Whichever comes first. So if you fly 100 hours a year, you'd hit the hour limit in 20 years. But you'd hit the calendar limit in just 12 years.

Why the calendar limit? Because engines that sit tend to develop problems. Moisture gets inside and causes corrosion. Seals dry out and crack. The camshaft can rust if the plane sits too long between flights. Engines need to run to stay healthy.

Here's something important that every pilot should know. For private owners flying under Part 91 rules, the TBO is a recommendation. It's not a legal requirement. You can fly past TBO if your engine is still in good shape.

Signs Your Engine Might Need Work Sooner

Sometimes engines don't make it to TBO. Watch for these warning signs:

Flying Past TBO

Many owners choose to fly "on condition" past the recommended TBO. This means they keep flying as long as the engine checks out healthy. Some IO-series engines have gone 3,000, 4,000, or even 5,000 hours this way.

The key is careful monitoring. Regular oil analysis. Frequent compression checks. Borescope inspections to look at the cylinders and camshaft. If everything looks good, you keep flying. When something changes, you address it.

This approach can save money. But it also carries some risk. And it might affect your plane's resale value. A plane with an engine past TBO will sell for less than one with a fresh overhaul.

Calendar Time Matters Too

Don't forget about that 12-year limit. Even if your engine only has 500 hours on it, age takes a toll. Rubber seals get brittle. Gaskets deteriorate. Internal parts can corrode if the plane wasn't flown regularly.

A low-time engine that's been sitting for years might actually need more work than a higher-time engine that flew every week. Regular use keeps oil flowing and prevents moisture buildup. That's why the experts always say: fly your plane often, and fly it long enough to get the oil hot.

Factory vs. Field Overhaul: What's the Difference?

This is one of the biggest decisions you'll make. Do you send your engine to Lycoming? Or do you use an independent shop? Let's break down your options.

Factory Rebuilt Engines

A factory new rebuild comes straight from Lycoming's facility in Pennsylvania. They take your old engine as a core and send you a completely remanufactured unit. Here's what makes it special:

The catch? It costs around $64,000 to $75,000 plus your core, depending on the engine model. And right now, the wait time is brutal. We're talking 27 to 30 months. That's over two years! They also want a 20% deposit upfront while you wait.

Only the factory can give an engine zero total time. This is a big deal for resale value. A zero-time engine is worth more than an overhauled one.

Factory Overhauled Engines

Lycoming also offers a factory overhaul option. This costs about $58,000 to $68,000 depending on the model. The engine is built to "service limits" rather than new limits. It keeps its original serial number and total time. You get zero time since major overhaul, but the total hours stay in the logbook.

Same long wait times apply here too.

Field Overhauls by Independent Shops

Independent shops like Penn Yan, Zephyr, and others do the same basic work. They take your engine apart, inspect everything, replace worn parts, and put it back together. The difference is in the paperwork.

A field overhaul:

Pricing ranges from $32,000 to $65,000 depending on the shop, engine model, and what's included. Turnaround is much faster—usually 3 to 5 months instead of years.

How Does Continental Compare?

Continental engines work similarly but have their own factory and shops. If you're comparing an IO-360 to a Continental option, the overhaul process is about the same. Continental also offers rebuild and overhaul programs through their factory.

Which Should You Choose?

For most owners, a quality field overhaul makes the most sense. You get essentially the same engine for less money and a fraction of the wait time. The main advantage of a factory rebuild is that zero-time logbook, which adds resale value.

Think about your situation:

Either way, choose a reputable shop with a good warranty. Ask for references. Talk to other owners who've used them. A quality overhaul from a good shop will serve you just as well as a factory job.

How Much Does It Really Cost to Overhaul an IO-Series Engine?

Now we get to the big question. The one that keeps airplane owners up at night. How much will this actually cost?

The short answer is somewhere between $28,000 and $85,000. That's a huge range, I know. The final number depends on many factors. Where you get the work done. What parts you choose. What condition your engine is in when it goes to the shop. Whether you have a four-cylinder or six-cylinder engine. Let's break it all down so you can plan your budget.

Current Pricing from Lycoming Factory (2025)

Going straight to Lycoming for your engine overhaul gives you the most options. But it also comes with the highest prices and longest wait times.

Here's what the factory charges right now for four-cylinder engines:

Six-cylinder IO-540 engines run approximately $10,000 to $15,000 more for each option.

The "core" is your old engine. You send it to them, and they use salvageable parts in their pool. If your core has major damage or missing parts, you'll pay extra penalties. Understanding what makes a Cessna 172 part unairworthy for resale can help you know if your core will pass inspection or trigger penalty charges.

The factory rebuild gives you that zero-time logbook entry. Your engine starts fresh at 0 hours. This matters for resale value. A factory new engine costs almost double, but everything inside is brand new.

Here's the painful part. Lead times at the factory are brutal right now. We're talking 27 to 30 months. That's over two years of waiting. They also want 20% upfront as a deposit. So you're giving them $12,000 or more and then waiting two-plus years to get your engine.

For many owners in general aviation, this wait time makes the factory option impractical. If your engine quits tomorrow, you can't wait two years to fly again.

Independent Shop Pricing (2025)

Independent overhaul shops offer a faster and usually cheaper alternative. These are FAA-certified facilities that specialize in engine work. Many have been doing this for decades.

Pricing varies by shop reputation and what's included:

The IO-360 falls in the middle of the pricing range for four-cylinder engines. Simpler carbureted engines like the O-360 cost a bit less. Six-cylinder IO-540 engines run $10,000 to $15,000 more due to the extra cylinders and larger components. The IO-320 typically costs slightly less than the IO-360.

Turn-around time is much better at independent shops. Most quote 12 to 16 weeks. Some can do it faster if parts are available. That's months instead of years.

Every pilot should get quotes from at least three shops before deciding. Prices can vary by $10,000 or more for the same work. Ask exactly what's included. Some quotes look cheap but don't include cylinders or accessories.

What's Typically Included in the Price

A good overhaul cost quote should spell out exactly what you're getting. Here's what most reputable shops include:

Engine internals:

Ignition system:

Fuel system:

Other items:

Read the fine print carefully. Some shops list these as included. Others list them as additional charges. A quote that looks $5,000 cheaper might actually cost more once you add everything up.

Hidden Costs That Add Up Fast

Here's what catches many owners off guard. The engine overhaul price is only part of the total bill. Getting that engine out of your aircraft, fixing related items, and putting it back takes more money.

Removal and reinstallation costs:

Propeller work:

Accessories and parts:

Shipping:

Unexpected repairs:

Add all this up and your total "all-in" cost typically lands between $38,000 and $85,000. A pilot budgeting only for the engine overhaul quote gets a nasty surprise when the final bills come in.

Ways to Save Money on Your Overhaul

You can't avoid this expense forever. But you can make smart choices to keep costs reasonable.

Choose overhauled cylinders instead of new ones. New Lycoming cylinders cost about $4,000 more than quality overhauled units. If your cylinders are first-run (never been overhauled before), they're often good candidates for overhaul. Many shops prefer Superior Millennium aftermarket cylinders, which cost less and work great.

Consider an IRAN instead of a full overhaul. IRAN stands for Inspect and Repair As Necessary. Instead of replacing everything, the mechanic only fixes what needs fixing. This can cost $20,000 to $32,000 depending on the engine model, with a six-week turnaround. It doesn't give you the same peace of mind as a full overhaul. But for an older plane or tight budget, it's worth considering.

Get multiple quotes and compare carefully. Call at least three shops. Ask for itemized quotes. Make sure you're comparing the same scope of work. A shop that seems expensive might include items that others charge extra for.

Plan ahead to avoid rush fees. If you wait until your engine fails, you'll pay premium prices for fast service. Start shopping when you hit 1,500 hours. Have your overhaul lined up before you need it.

Do some work yourself under supervision. If you're handy and have a good relationship with an A&P mechanic, you can help with removal and reinstallation. This can save $1,000 to $2,000 in labor. Just make sure an IA signs off all the work.

Compared to Continental options. If you're doing a major rebuild anyway, some owners explore engine swaps. A Continental engine might fit your airframe with an STC. Sometimes the math works out better. This is a bigger project, but worth researching.

How Your Engine Time Affects Other Costs

Your engine hours don't just affect overhaul timing. They ripple into other ownership expenses too. Learning about how engine time affects insurance on a Cessna 172 shows you the full picture. Insurance companies look closely at engine time when setting your premiums. A high-time engine near TBO often means higher rates. A freshly overhauled engine can actually lower your annual insurance costs.

The bottom line? Budget $45,000 to $70,000 for a quality four-cylinder IO-series overhaul with all related costs. Six-cylinder engines like the IO-540 should budget $55,000 to $85,000. You might spend less if everything goes smoothly. You might spend more if surprises pop up. Having realistic expectations helps you plan and avoid stress when the bills arrive.

 

Conclusion

Planning for your Lycoming IO-series overhaul cost takes time and research. But now you know what to expect. Budget somewhere between $38,000 and $85,000 for the complete job, depending on your engine model and choices. Factory rebuilds offer that valuable zero-time logbook but come with long waits and higher prices. Independent shops deliver quality work faster and for less money.

Start planning early. Get multiple quotes. Ask questions about what's included and what's extra. And remember that regular flying and good maintenance can help your engine last longer before you need this major expense.

A properly overhauled IO-series engine will give you thousands of hours of reliable service. It's a big investment, but it's also a peace of mind every time you take to the sky.

Ready to learn more about aircraft ownership and maintenance? Check out Flying 411 for more guides, tips, and resources to help you make smart decisions about your airplane.

Frequently Asked Questions

Can I overhaul my IO-series engine myself to save money?

You can do some of the work under A&P supervision, but an IA (Inspection Authorization) holder must sign off the final work. Many owners help with disassembly and reassembly to reduce labor costs. The engine must meet all FAA requirements before returning to service.

How long does an IO-series overhaul take?

Independent shops typically complete overhauls in 12 to 16 weeks. Factory rebuilds currently take 27 to 30 months due to backlogs. Add another week or two for removal and reinstallation at your local shop.

Does an overhaul increase my airplane's value?

Yes, but not dollar for dollar. A $60,000 overhaul might add $25,000 to $35,000 in resale value. Buyers pay more for fresh engines, but you rarely recover the full cost. Time your overhaul based on your needs, not just resale.

What is an IRAN and how is it different from an overhaul?

IRAN stands for Inspect and Repair As Necessary. Instead of replacing everything, the mechanic only fixes what needs fixing. It costs less ($20,000-$32,000 depending on engine model) but doesn't reset the clock or provide the same peace of mind as a full overhaul.

Are aftermarket cylinders as good as Lycoming cylinders?

Superior Millennium cylinders and other aftermarket options are FAA-approved and widely used. Many mechanics prefer them. They often cost less and may be easier to get. Quality aftermarket parts work great in overhauled engines.Meta Description: Learn the true Lycoming IO-series engine overhaul cost in 2025. Get pricing from factory and shop options, plus tips to save money on your engine overhaul.

Article Tags: Aircraft Maintenance, Aircraft Ownership, General Aviation

Lycoming IO-Series Engine Overhaul Cost and Time to Expect

Your engine has been running great for years. But now you're getting close to that 2,000-hour mark. Or maybe you've noticed it's using more oil than it used to. Either way, you're starting to think about the big one: an engine overhaul.

If you own an airplane with a Lycoming IO-series engine, you're in good company. These engines power some of the most popular planes in general aviation. The IO-360 runs in the Cessna 172, Piper Arrow, and Grumman Tiger. The IO-540 powers the Piper Cherokee Six and Cessna 206. 

The smaller IO-320 is found in trainers and light singles. All of these are part of the same proven engine family. The IO-Series engine family was first certified back in 1955, and since then it's been installed in thousands of aircraft. That's nearly 70 years of proven performance. It's known for being tough and reliable. But even the best engines need a refresh eventually.

Here's the hard truth. The overhaul cost for these engines has gone up a lot in recent years. We're talking about a big investment. Depending on your choices, you could spend anywhere from $28,000 to over $85,000. That's a wide range, and a lot of factors affect where you'll land.

The good news? You have options. You can go with a factory overhaul or choose an independent shop. You can pick new parts or overhauled ones. You can even fly past the recommended time if your engine is healthy. Understanding these choices helps you plan better and maybe even save some money.

This post explains what you'll actually pay and what affects your final bill.

Key Takeaways

How much does an IO-Series overhaul cost? A Lycoming IO-series overhaul typically costs between $28,000 and $75,000 for the engine work alone, depending on the engine model. Four-cylinder engines like the IO-320 and IO-360 fall on the lower end. Six-cylinder engines like the IO-540 cost more due to additional parts and labor. Factory rebuilds run about $64,000 to $75,000 plus a core charge, while independent shops charge $32,000 to $65,000. Add another $5,000 to $10,000 for removal, reinstallation, propeller work, and accessories. Your total "all-in" cost will likely fall between $38,000 and $85,000 depending on your choices.

OptionIO-320/IO-360 CostIO-540 CostTotal Estimated Cost
Factory Rebuild$64,000 + core$75,000 + core$70,000 - $85,000
Factory Overhaul$58,000 + core$68,000 + core$65,000 - $80,000
Major Shop Overhaul$33,000 - $53,000$45,000 - $65,000$40,000 - $75,000
Local Shop Overhaul$32,000 - $41,000$40,000 - $55,000$38,000 - $65,000
IRAN (Inspect/Repair)$20,000 - $25,000$25,000 - $32,000$28,000 - $42,000

What Is an Engine Overhaul?

Think of an engine overhaul like a complete rebuild of your car's motor. The mechanic takes the whole thing apart, piece by piece. They clean everything. They inspect every part. Then they replace anything that's worn out. Finally, they put it all back together and test it.

For your O-360 or IO-360, this process follows strict rules set by the manufacturer. The engine shop will:

What Parts Get Replaced?

During a typical overhaul, several key components almost always get replaced. The cylinder assemblies usually get new or rebuilt units. The camshaft often needs replacing because it wears down over time. The crankshaft gets inspected and sometimes reground to bring it back to spec.

Here's a general list of what gets attention:

Why Do Engines Need Overhauls?

Every time your engine runs, metal parts rub against each other. Even with good oil, this causes tiny amounts of wear. Over thousands of hours, that wear adds up. Tolerances that were once tight become loose. Compression drops. Performance suffers.

An overhaul brings everything back to like-new condition. It restores the power your engine made when it was fresh. More importantly, it keeps you safe. A well-maintained engine is far less likely to have problems in flight.

The process also lets mechanics find hidden issues. A crack in the crankcase. A worn bearing about to fail. Corrosion starting on internal parts. Catching these problems during an overhaul prevents them from becoming emergencies later.

An engine overhaul is a major event in your airplane's life. It's expensive and time-consuming. But it's also an investment in safety and performance. A properly overhauled IO-series engine can run another 2,000 hours or more. That's potentially another 10 to 20 years of reliable flying, depending on how much you use the plane.

When Does Your IO-Series Engine Need an Overhaul?

The short answer? When the manufacturer recommends it, or when your engine tells you it needs one. Let's look at both.

The Official Recommendation

Lycoming sets what's called a TBO, which stands for Time Between Overhaul. For most IO-series engines, the TBO is 2,000 hours or 12 years. Some models vary slightly. The IO-320 and IO-360 share this 2,000-hour recommendation. The IO-540 also carries a 2,000-hour TBO in most configurations. Whichever comes first. So if you fly 100 hours a year, you'd hit the hour limit in 20 years. But you'd hit the calendar limit in just 12 years.

Why the calendar limit? Because engines that sit tend to develop problems. Moisture gets inside and causes corrosion. Seals dry out and crack. The camshaft can rust if the plane sits too long between flights. Engines need to run to stay healthy.

Here's something important that every pilot should know. For private owners flying under Part 91 rules, the TBO is a recommendation. It's not a legal requirement. You can fly past TBO if your engine is still in good shape.

Signs Your Engine Might Need Work Sooner

Sometimes engines don't make it to TBO. Watch for these warning signs:

Flying Past TBO

Many owners choose to fly "on condition" past the recommended TBO. This means they keep flying as long as the engine checks out healthy. Some IO-series engines have gone 3,000, 4,000, or even 5,000 hours this way.

The key is careful monitoring. Regular oil analysis. Frequent compression checks. Borescope inspections to look at the cylinders and camshaft. If everything looks good, you keep flying. When something changes, you address it.

This approach can save money. But it also carries some risk. And it might affect your plane's resale value. A plane with an engine past TBO will sell for less than one with a fresh overhaul.

Calendar Time Matters Too

Don't forget about that 12-year limit. Even if your engine only has 500 hours on it, age takes a toll. Rubber seals get brittle. Gaskets deteriorate. Internal parts can corrode if the plane wasn't flown regularly.

A low-time engine that's been sitting for years might actually need more work than a higher-time engine that flew every week. Regular use keeps oil flowing and prevents moisture buildup. That's why the experts always say: fly your plane often, and fly it long enough to get the oil hot.

Factory vs. Field Overhaul: What's the Difference?

This is one of the biggest decisions you'll make. Do you send your engine to Lycoming? Or do you use an independent shop? Let's break down your options.

Factory Rebuilt Engines

A factory new rebuild comes straight from Lycoming's facility in Pennsylvania. They take your old engine as a core and send you a completely remanufactured unit. Here's what makes it special:

The catch? It costs around $64,000 to $75,000 plus your core, depending on the engine model. And right now, the wait time is brutal. We're talking 27 to 30 months. That's over two years! They also want a 20% deposit upfront while you wait.

Only the factory can give an engine zero total time. This is a big deal for resale value. A zero-time engine is worth more than an overhauled one.

Factory Overhauled Engines

Lycoming also offers a factory overhaul option. This costs about $58,000 to $68,000 depending on the model. The engine is built to "service limits" rather than new limits. It keeps its original serial number and total time. You get zero time since major overhaul, but the total hours stay in the logbook.

Same long wait times apply here too.

Field Overhauls by Independent Shops

Independent shops like Penn Yan, Zephyr, and others do the same basic work. They take your engine apart, inspect everything, replace worn parts, and put it back together. The difference is in the paperwork.

A field overhaul:

Pricing ranges from $32,000 to $65,000 depending on the shop, engine model, and what's included. Turnaround is much faster—usually 3 to 5 months instead of years.

How Does Continental Compare?

Continental engines work similarly but have their own factory and shops. If you're comparing an IO-360 to a Continental option, the overhaul process is about the same. Continental also offers rebuild and overhaul programs through their factory.

Which Should You Choose?

For most owners, a quality field overhaul makes the most sense. You get essentially the same engine for less money and a fraction of the wait time. The main advantage of a factory rebuild is that zero-time logbook, which adds resale value.

Think about your situation:

Either way, choose a reputable shop with a good warranty. Ask for references. Talk to other owners who've used them. A quality overhaul from a good shop will serve you just as well as a factory job.

How Much Does It Really Cost to Overhaul an IO-Series Engine?

Now we get to the big question. The one that keeps airplane owners up at night. How much will this actually cost?

The short answer is somewhere between $28,000 and $85,000. That's a huge range, I know. The final number depends on many factors. Where you get the work done. What parts you choose. What condition your engine is in when it goes to the shop. Whether you have a four-cylinder or six-cylinder engine. Let's break it all down so you can plan your budget.

Current Pricing from Lycoming Factory (2025)

Going straight to Lycoming for your engine overhaul gives you the most options. But it also comes with the highest prices and longest wait times.

Here's what the factory charges right now for four-cylinder engines:

Six-cylinder IO-540 engines run approximately $10,000 to $15,000 more for each option.

The "core" is your old engine. You send it to them, and they use salvageable parts in their pool. If your core has major damage or missing parts, you'll pay extra penalties. Understanding what makes a Cessna 172 part unairworthy for resale can help you know if your core will pass inspection or trigger penalty charges.

The factory rebuild gives you that zero-time logbook entry. Your engine starts fresh at 0 hours. This matters for resale value. A factory new engine costs almost double, but everything inside is brand new.

Here's the painful part. Lead times at the factory are brutal right now. We're talking 27 to 30 months. That's over two years of waiting. They also want 20% upfront as a deposit. So you're giving them $12,000 or more and then waiting two-plus years to get your engine.

For many owners in general aviation, this wait time makes the factory option impractical. If your engine quits tomorrow, you can't wait two years to fly again.

Independent Shop Pricing (2025)

Independent overhaul shops offer a faster and usually cheaper alternative. These are FAA-certified facilities that specialize in engine work. Many have been doing this for decades.

Pricing varies by shop reputation and what's included:

The IO-360 falls in the middle of the pricing range for four-cylinder engines. Simpler carbureted engines like the O-360 cost a bit less. Six-cylinder IO-540 engines run $10,000 to $15,000 more due to the extra cylinders and larger components. The IO-320 typically costs slightly less than the IO-360.

Turn-around time is much better at independent shops. Most quote 12 to 16 weeks. Some can do it faster if parts are available. That's months instead of years.

Every pilot should get quotes from at least three shops before deciding. Prices can vary by $10,000 or more for the same work. Ask exactly what's included. Some quotes look cheap but don't include cylinders or accessories.

What's Typically Included in the Price

A good overhaul cost quote should spell out exactly what you're getting. Here's what most reputable shops include:

Engine internals:

Ignition system:

Fuel system:

Other items:

Read the fine print carefully. Some shops list these as included. Others list them as additional charges. A quote that looks $5,000 cheaper might actually cost more once you add everything up.

Hidden Costs That Add Up Fast

Here's what catches many owners off guard. The engine overhaul price is only part of the total bill. Getting that engine out of your aircraft, fixing related items, and putting it back takes more money.

Removal and reinstallation costs:

Propeller work:

Accessories and parts:

Shipping:

Unexpected repairs:

Add all this up and your total "all-in" cost typically lands between $38,000 and $85,000. A pilot budgeting only for the engine overhaul quote gets a nasty surprise when the final bills come in.

Ways to Save Money on Your Overhaul

You can't avoid this expense forever. But you can make smart choices to keep costs reasonable.

Choose overhauled cylinders instead of new ones. New Lycoming cylinders cost about $4,000 more than quality overhauled units. If your cylinders are first-run (never been overhauled before), they're often good candidates for overhaul. Many shops prefer Superior Millennium aftermarket cylinders, which cost less and work great.

Consider an IRAN instead of a full overhaul. IRAN stands for Inspect and Repair As Necessary. Instead of replacing everything, the mechanic only fixes what needs fixing. This can cost $20,000 to $32,000 depending on the engine model, with a six-week turnaround. It doesn't give you the same peace of mind as a full overhaul. But for an older plane or tight budget, it's worth considering.

Get multiple quotes and compare carefully. Call at least three shops. Ask for itemized quotes. Make sure you're comparing the same scope of work. A shop that seems expensive might include items that others charge extra for.

Plan ahead to avoid rush fees. If you wait until your engine fails, you'll pay premium prices for fast service. Start shopping when you hit 1,500 hours. Have your overhaul lined up before you need it.

Do some work yourself under supervision. If you're handy and have a good relationship with an A&P mechanic, you can help with removal and reinstallation. This can save $1,000 to $2,000 in labor. Just make sure an IA signs off all the work.

Compared to Continental options. If you're doing a major rebuild anyway, some owners explore engine swaps. A Continental engine might fit your airframe with an STC. Sometimes the math works out better. This is a bigger project, but worth researching.

How Your Engine Time Affects Other Costs

Your engine hours don't just affect overhaul timing. They ripple into other ownership expenses too. Learning about how engine time affects insurance on a Cessna 172 shows you the full picture. Insurance companies look closely at engine time when setting your premiums. A high-time engine near TBO often means higher rates. A freshly overhauled engine can actually lower your annual insurance costs.

The bottom line? Budget $45,000 to $70,000 for a quality four-cylinder IO-series overhaul with all related costs. Six-cylinder engines like the IO-540 should budget $55,000 to $85,000. You might spend less if everything goes smoothly. You might spend more if surprises pop up. Having realistic expectations helps you plan and avoid stress when the bills arrive.

 

Conclusion

Planning for your Lycoming IO-series overhaul cost takes time and research. But now you know what to expect. Budget somewhere between $38,000 and $85,000 for the complete job, depending on your engine model and choices. Factory rebuilds offer that valuable zero-time logbook but come with long waits and higher prices. Independent shops deliver quality work faster and for less money.

Start planning early. Get multiple quotes. Ask questions about what's included and what's extra. And remember that regular flying and good maintenance can help your engine last longer before you need this major expense.

A properly overhauled IO-series engine will give you thousands of hours of reliable service. It's a big investment, but it's also a peace of mind every time you take to the sky.

Ready to learn more about aircraft ownership and maintenance? Check out Flying 411 for more guides, tips, and resources to help you make smart decisions about your airplane.

Frequently Asked Questions

Can I overhaul my IO-series engine myself to save money?

You can do some of the work under A&P supervision, but an IA (Inspection Authorization) holder must sign off the final work. Many owners help with disassembly and reassembly to reduce labor costs. The engine must meet all FAA requirements before returning to service.

How long does an IO-series overhaul take?

Independent shops typically complete overhauls in 12 to 16 weeks. Factory rebuilds currently take 27 to 30 months due to backlogs. Add another week or two for removal and reinstallation at your local shop.

Does an overhaul increase my airplane's value?

Yes, but not dollar for dollar. A $60,000 overhaul might add $25,000 to $35,000 in resale value. Buyers pay more for fresh engines, but you rarely recover the full cost. Time your overhaul based on your needs, not just resale.

What is an IRAN and how is it different from an overhaul?

IRAN stands for Inspect and Repair As Necessary. Instead of replacing everything, the mechanic only fixes what needs fixing. It costs less ($20,000-$32,000 depending on engine model) but doesn't reset the clock or provide the same peace of mind as a full overhaul.

Are aftermarket cylinders as good as Lycoming cylinders?

Superior Millennium cylinders and other aftermarket options are FAA-approved and widely used. Many mechanics prefer them. They often cost less and may be easier to get. Quality aftermarket parts work great in overhauled engines.