Since about the year 2000, cast aluminum automobile engine blocks have been coated in production lines using internal plasma spraying technology. Using this approach, the coefficient of friction between the cylinder wall and the piston assembly can be reduced to 30% and oil consumption is reduced of a factor two in comparison with cast iron. The extremely low wear rate of the friction elements increases engine life and reduces maintenance costs. The fuel consumption of the cars can be reduced from 2 to 4% in the case of gasoline and diesel engines. The coating costs are strongly dependent on production volume. For high volume production, the costs can be similar to those for cast iron liners. This paper reviews results from laboratory and field tests evaluating the performance and cost efficiency of plasma sprayed engine block liners.