The Cirrus SR22 and the Mooney Ovation Ultra are both high-performance, complex single-engine aircraft that demand meticulous maintenance. While both feature advanced Continental IO-550 engines and Garmin G1000 NXi avionics, their design philosophies, particularly the Cirrus’s composite airframe and parachute system versus the Mooney’s all-metal construction, lead to distinct considerations for annual inspections and engine overhauls. Generally, the Cirrus SR22 often presents higher costs and more specialized requirements for annuals due to its CAPS system and composite structure, while engine overhauls for both are similarly expensive, but the Cirrus SR22T (turbocharged variant) adds another layer of complexity.
CIRRUS SR22 (AND SR22T): MODERN COMPLEXITY AND PROPRIETARY SYSTEMS
The Cirrus SR22’s composite airframe, integrated glass cockpit, and especially the Cirrus Airframe Parachute System (CAPS) significantly influence annual inspection costs and long-term maintenance.
Annual Inspections:
- Higher Base Cost: A standard annual inspection for an SR22 generally ranges from $2,500 to $10,000+ USD, with many owners reporting averages around $5,000 to $7,000. This is often higher than a comparable all-metal aircraft. The turbocharged SR22T may be on the higher end due to additional components to inspect.
- Composite Inspection: Mechanics must meticulously inspect the composite airframe for any signs of delamination, cracks, or impact damage. While less prone to corrosion, composite repairs are highly specialized and often lead to higher labor rates and materials if needed.
- CAPS System Inspection & Repack: This is a major differentiating factor. The CAPS system requires specific inspections annually, and a mandatory repack (replacement of the parachute and rocket motor) every 10 years.
- Cost: A CAPS repack can cost anywhere from $15,000 to $35,000+ USD, depending on the model year (some earlier models require more extensive work or component upgrades during repack) and the service center. This is a significant, unavoidable lump sum expense that must be factored into the budget every decade. This cost can sometimes include paint touch-ups due to the removal of components.
- Advanced Avionics Inspection: The Garmin Perspective+ (customized G1000 NXi) requires detailed checks of all systems, sensors, and software. While generally reliable, any identified issues with LRUs (Line Replaceable Units) can be very expensive to replace.
- Turbine Inlet/Exhaust (SR22T): The turbocharged SR22T requires additional inspection of the turbocharger, intercooler, and exhaust system, which can be prone to cracking or wear, adding complexity and potential cost to the annual.
Engine Overhauls:
- Continental IO-550-N (SR22) / TSIO-550-K (SR22T): Both use variants of the Continental 550 series.
- Overhaul Cost: A factory-rebuilt or overhauled Continental IO-550-N/K typically costs $60,000 to $100,000+ USD, depending on accessories, engine shop rates, and any unexpected repairs found during teardown. This is an industry-standard cost for high-horsepower piston engines.
- TBO (Time Between Overhaul): Continental engines generally have a TBO of 2,000 hours, but actual time before overhaul can vary based on operational use and condition.
- TSIO-550-K Complexity: The turbocharged, FADEC-controlled TSIO-550-K in the SR22T adds complexity to the overhaul process. While the core engine is similar, the turbocharging system and FADEC components require specialized expertise during overhaul.
MOONEY OVATION ULTRA: ALL-METAL PRECISION AND CONVENTIONAL ENGINE
The Mooney Ovation Ultra (M20U) combines Mooney’s signature speed and efficiency with an all-metal airframe and a high-performance Continental engine.
Annual Inspections:
- Moderate Base Cost: Annual inspections for a Mooney Ovation Ultra typically range from $3,000 to $8,000+ USD. While not as low as a simple trainer, it’s often slightly less than an SR22 if no major squawks are found, largely due to the absence of the CAPS system.
- Metal Airframe Inspection: Mechanics will focus on inspecting the aluminum airframe for common issues like corrosion, particularly in hidden areas, and checking for any signs of metal fatigue around stress points (e.g., wing attachment, landing gear pivots).
- Retractable Gear Inspection: The Mooney’s retractable landing gear system requires thorough inspection of hydraulics (if applicable), electric motors, actuators, and associated wiring. This adds complexity compared to fixed-gear aircraft.
- Garmin G1000 NXi: Similar to the Cirrus, the Ovation Ultra features a sophisticated Garmin G1000 NXi suite. Avionics inspections are thorough, and LRU replacements can be expensive if needed.
Engine Overhauls:
- Continental IO-550-G: The Ovation Ultra is powered by the naturally aspirated Continental IO-550-G.
- Overhaul Cost: Overhaul costs for this engine are comparable to the SR22’s engine, typically $60,000 to $100,000+ USD, depending on the engine shop, scope of work (e.g., new cylinders vs. re-worked), and accessory overhauls.
- TBO: The IO-550-G also has a TBO of 2,000 hours.
- Less Turbo Complexity: Being naturally aspirated, the IO-550-G avoids the added complexity and potential maintenance items (e.g., turbocharger, intercooler) associated with a turbocharged engine found in the SR22T, which can sometimes lead to slightly lower overall engine-related maintenance costs over its life.
COST COMPARISON: ANNUALS AND OVERHAULS
- Annuals: The Cirrus SR22 generally has higher annual inspection costs due to the mandatory CAPS repack every 10 years, which adds a significant, unique expense. The composite structure can also lead to more specialized (and thus potentially pricier) repairs if damage occurs. The base annual for both without major issues is relatively similar, but the CAPS system is the game-changer for the SR22.
- Engine Overhauls: Engine overhaul costs for both aircraft are broadly similar, as they use variants of the same Continental 550 series engine, ranging from $60,000 to $100,000+ USD. The turbocharged nature of the SR22T’s engine might introduce a few more potential failure points (turbocharger, exhaust system) over its lifespan, but the core overhaul cost is comparable.
For owners in California, Arizona, or Nevada, access to highly specialized service centers for both Cirrus and Mooney is available in major aviation hubs. These centers are equipped with the specific tooling and factory training required for these complex aircraft. The significant costs associated with these annuals and overhauls mean that owners must diligently budget for them. In Lipa City, Calabarzon, Philippines, the average monthly salary for an aircraft mechanic ranges from ₱35,000 to ₱45,000 (approximately $590 to $760 USD, as of July 2025). While this indicates lower labor costs than in Western countries, the sheer cost of parts (engines, avionics LRUs, CAPS components) will still be high, as these are globally priced items. Specialized facilities for CAPS repacks or complex engine overhauls might be limited to major MROs in the Philippines, potentially requiring aircraft ferrying and extending downtime, even with lower local labor rates.
The Aero Center is fully equipped to handle the rigorous demands of annual inspections and engine overhauls for both the Cirrus SR22 and the Mooney Ovation Ultra. Serving California, Arizona, and Nevada, we are the only 24/7 maintenance center in the region, dedicated to minimizing your aircraft’s downtime. Our authority in meticulously performing these critical maintenance events, from complex CAPS repacks on the Cirrus to comprehensive engine overhauls on both platforms, is built on the consistent delivery of high-quality service, reinforced by the social proof of countless satisfied clients who trust us with their valuable assets. We ensure your aircraft receives expert care, maintaining its airworthiness and performance, day or night.
The Aero Center is located at William J. Fox Airfield KWJF | Lancaster, CA. Contact us at 209.885.6950 for questions or appointments.
FOOTNOTES
- Cirrus Owners and Pilots Association (COPA) Forums: Extensive discussions and real-world cost reporting by Cirrus owners on annuals, CAPS repacks, and engine overhauls.
- Aircraft Cost Calculator: Provides estimated annual and hourly operating costs, including maintenance and engine reserves for various aircraft, including the Cirrus SR22 and Mooney M20R Ovation.
- Air Power Inc. & Western Skyways: Major engine overhaul facilities listing pricing for Continental IO-550 series engines.
- All In Aviation Maintenance: Specific information on Cirrus SR22 parachute repack costs.
- Planephd.com: Operating cost breakdowns for the Mooney M20V Acclaim Ultra, including annual inspection estimates.
- Jobstreet Philippines & Payscale Philippines: Current salary data for aircraft mechanics in the Philippines, providing context for local labor rates.