Air India Grounds Boeing 787 Dreamliner Over Critical Fuel Control Switch Issue
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Air India grounded Boeing 787 VT-ANX following a London-Bengaluru flight after the crew reported the left engine's fuel control switch repeatedly moved toward CUTOFF.
Key Takeaways
- •Air India grounded Boeing 787 VT-ANX after the crew reported the left engine's fuel control switch failed to lock in the 'RUN' position twice during engine start at London Heathrow.
- •The DGCA is probing the incident, which involves a component at the center of the investigation into the fatal Air India Flight 171 crash in June 2025.
- •Air India initiated a precautionary fleet-wide re-inspection of the fuel control switches across its entire fleet of 33 Boeing 787 Dreamliners.
- •The switch module is being sent to the Original Equipment Manufacturer (OEM), Honeywell, for priority evaluation and inspection.
Air India has grounded a Boeing 787-8 Dreamliner, registration VT-ANX, after its flight crew reported an abnormal issue with the left engine's fuel control switch (FCS). The aircraft, which operated a recent London to Bengaluru flight, was immediately taken out of service upon landing. This incident has prompted an official aircraft safety investigation by India’s aviation regulator.
Incident Details
The incident occurred on the flight from London Heathrow (LHR) to Bengaluru (BLR). The crew first noted the engine fuel control switch issue during the engine start sequence at LHR. According to a statement from the Directorate General of Civil Aviation (DGCA), the crew observed that the left engine's fuel control switch did not remain positively latched in the 'RUN' position on two separate occasions when light pressure was applied. The switch was reportedly moving toward the 'CUTOFF' position.
Fuel control switches are critical components. They control the flow of fuel to the engine. Movement to the 'CUTOFF' position would starve the engine of fuel, causing an engine shutdown risk in flight. The switches are typically protected by a stop-lock mechanism to prevent accidental activation.
On the third attempt, the crew successfully latched the switch into the 'RUN' position. The crew then performed a physical verification to confirm the switch was fully engaged. The flight, AI132, proceeded to Bengaluru without further reported abnormal engine parameters or warnings. Following the aircraft's safe arrival, Air India grounded the nine-year-old aircraft for detailed inspection. The airline stated that passenger and crew safety remains its highest priority.
Regulatory and Fleet Response
The DGCA probe VT-ANX is now underway. The regulator has been informed of the issue and is reviewing the circumstances of the flight. The DGCA also advised Air India to circulate recommended Boeing procedures to its crew. This ensures proper operation of the fuel cut-off switches.
In a precautionary move, Air India initiated a fleet-wide re-inspection of the fuel control switch latch on its entire fleet of 33 Boeing 787 wide-body jets. This action is taken out of an abundance of caution, according to airline sources. The airline is working with the Original Equipment Manufacturer (OEM) for inspection and evaluation of the switch module. The fuel control switch manufacturer is Honeywell.
Safety Context and Industry Impact
This specific Boeing 787 maintenance issue is under intense scrutiny. The incident comes amid a separate, ongoing investigation into the fatal Air India Flight 171 crash in June 2025. The preliminary report for that accident indicated that both engine fuel control switches had moved to the 'CUTOFF' position shortly after takeoff, starving the engines of fuel.
While the DGCA noted that pre-flight checks on VT-ANX were completed, the reported defect highlights the criticality of switch integrity. The Air India Boeing 787 grounding and subsequent fleet-wide checks underscore the industry's commitment to proactive safety measures. The DGCA's findings and the OEM's analysis will be key to determining the cause. They will clarify if the issue is an isolated mechanical fault, a fuel control switch failure design concern, or a procedural matter. The global aviation community will closely monitor the results of this aircraft safety investigation.
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Written by Ujjwal Sukhwani
Aviation News Editor & Industry Analyst delivering clear coverage for a worldwide audience. Covers flight operations, safety regulations, and market trends with expert analysis.
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