Why Did Air India Inspect Every Boeing 787 Fuel Control Switch?

Air India has confirmed the completion of precautionary re-inspections across its entire operational Boeing 787 fleet. The airline was checking the Fuel Control Switch (FCS) components. This fleet-wide action followed a pilot reported defect on a London-Bengaluru flight (AI132) earlier this week. The inspections found no mechanical issues with the switches.

Background to the Scrutiny

The incident occurred during engine start at London Heathrow Airport. The pilot reported that the left engine Fuel Control Switch did not positively latch in the 'RUN' position twice. On the third attempt, the switch locked correctly and the flight proceeded without incident.

The Directorate General of Civil Aviation (DGCA), India's aviation regulator, conducted its own independent checks. The DGCA found the switches on the grounded aircraft were "within safety norms." Their locking mechanisms aligned with Boeing's prescribed standards.

Crucially, the regulator’s probe suggested the switch movement occurred due to external force. This force was applied in an incorrect direction. The DGCA also noted that a social media video demonstrating the switch operation used an incorrect procedure.

Reinforcing Aviation Safety Protocols

Despite finding no defects, Air India is taking further steps. The airline will replace the specific switch module involved in the incident. This component will be sent to the manufacturer for detailed evaluation. This is being done even though the part has logged less than 20 percent of its certified service life.

Air India will also fully adhere to the DGCA's guidance. The airline will circulate OEM-recommended operating procedures for the FCS to all crew members. This step reinforces reporting and handling protocols for the fuel cut-off switch.

• The DGCA cleared the switches after finding no mechanical fault.
• The reported movement was attributed to incorrect force application.
• Air India will reinforce crew training on proper OEM-recommended operating procedures.

Wider Dreamliner Fleet Scrutiny

This latest event brings renewed attention to the Boeing 787 Dreamliner fleet scrutiny. The focus is on the fuel control system. This is especially significant given the ongoing investigation into the fatal Air India Flight AI171 crash.

That accident occurred in June 2025 in Ahmedabad. Preliminary reports indicated both engine fuel control switches moved to the 'CUTOFF' position. This happened moments after takeoff, causing a loss of thrust and the crash. The cause of the switch movement in the AI171 crash remains under investigation.

The recent pilot reported defect, though cleared of a mechanical fault, highlights the need for aviation safety protocols. It underscores the importance of strict adherence to OEM-recommended operating procedures. The swift response by Air India and the DGCA demonstrates a commitment to transparency and safety. This aims to maintain public confidence in the Air India Boeing 787 fleet.

From airline operations to fleet updates, commercial aviation news lives at flying.flights.

Follow aviation sustainability efforts, emissions research, and green initiatives in the Environmental section at flying.flights/environmental.