Aircraft Engine Overhaul Costs
Everything you need to know about engine overhauls, costs, and planning.
What is TBO?
Time Between Overhauls (TBO) is the manufacturer's recommended maximum operating time between engine overhauls.
Common Aircraft TBO Hours
- Lycoming O-235: 2,000 hours
- Lycoming O-360: 2,000 hours
- Continental O-200: 1,800 hours
- Lycoming O-540: 2,000 hours
- Continental IO-520: 1,700 hours
Example Timeline
- Aircraft bought: 1,200 hours
- TBO: 2,000 hours
- Hours remaining: 800
- At 100 hrs/yr: 8 years until overhaul
- Budget now for future!
Overhaul Costs by Engine
| Engine | HP | Overhaul Cost | Cost/Hour |
|---|---|---|---|
| Continental O-200 | 100 | $20,000-$25,000 | $11-$14 |
| Lycoming O-235 | 115 | $22,000-$28,000 | $11-$14 |
| Lycoming O-360 | 180 | $25,000-$32,000 | $12-$16 |
| Continental IO-360 | 180 | $28,000-$35,000 | $15-$20 |
| Lycoming O-540 | 260 | $32,000-$42,000 | $16-$21 |
| Continental IO-520 | 285 | $35,000-$45,000 | $20-$26 |
What's Included in an Overhaul?
Major Components Replaced
- Pistons & rings
- Cylinders & liners
- Crankshaft & bearings
- Connecting rods
- Gaskets & seals
- Spark plugs & ignition
Labor & Services
- 100+ hours machine shop time
- Assembly & testing
- Inspections & reports
- Modifications (optional)
- Reinstallation
- Test flight & certification
Timeline & Downtime
A typical engine overhaul takes 2-4 months from drop to reinstallation.
Timeline Example
- Week 1: Drop engine, send to overhaul facility
- Week 2-6: Disassembly & machining (4-6 weeks)
- Week 7-8: Assembly & testing
- Week 9-10: Return & reinstallation
- Week 11: Test flight & airworthiness
- Total: 10-12 weeks before flying again
How to Budget for Overhaul
Most aircraft owners budget for overhaul by setting aside money monthly.
Example: Cessna 172
- Engine: Lycoming O-360
- TBO: 2,000 hours
- Overhaul cost: $28,000
- Monthly reserve: $14/hour
- At 100 hrs/yr: $117/month
Reserve Fund Formula
Monthly reserve = (Overhaul cost ÷ TBO hours) × Average monthly hours
Example: ($28,000 ÷ 2,000) × (100/12) = $117/month
Options to Reduce Costs
Factory Overhaul
Cost: $28,000-$35,000
Official manufacturer overhaul. Highest quality, warranty included.
Field Overhaul
Cost: $22,000-$28,000
Done by certified A&P. Saves money, still quality work.
Remanufactured Engine
Cost: $15,000-$22,000
Use overhauled engine from another aircraft. Quick swap.
Top Overhaul
Cost: $5,000-$8,000
Only cylinders & pistons. Extends TBO 500-1,000 hours.
Factor Overhaul into Your Aircraft Budget
Use our ownership cost calculator to include engine overhaul reserves in your total aircraft cost projections.