Delhi, India: Air India has grounded one of its Boeing 787-8 Dreamliner aircraft after a pilot reported a possible defect in the fuel control switch mechanism, prompting a detailed inspection and coordination with the airframe manufacturer, Boeing.
The aircraft, operating as AI132 from London Heathrow to Bengaluru, landed safely at its destination on February 2, after the flight crew observed abnormal behaviour in the left engine’s fuel control switch during pre-flight engine checks, according to airline officials.
In a statement, Air India confirmed that a pilot flagged the issue and the aircraft was immediately taken out of service as a precautionary safety measure while the concern is investigated. The airline has informed the Directorate General of Civil Aviation (DGCA) and engaged Boeing to prioritise a technical evaluation.
“After receiving this initial information, we have grounded the aircraft and are involving the OEM (original equipment manufacturer) to get the pilot’s concerns checked on a priority basis,” an Air India spokesperson said. The matter has also been formally communicated to India’s aviation regulator, the DGCA.
Fuel control switches regulate the flow of fuel to an aircraft’s engines and are designed with safeguards to prevent unintended movement. On the Boeing 787, these switches must be lifted and then moved to change position, reducing the likelihood of accidental operation. However, if such a switch were to shift from the “RUN” to the “CUTOFF” position in flight, it would immediately halt fuel flow, leading to engine shutdown.
The focus on fuel control switch behaviour stems from the June 12, 2025 crash of Air India Flight AI-171, another Boeing 787-8, near Ahmedabad, which killed 260 people. A preliminary investigation by the Aircraft Accident Investigation Bureau (AAIB) found that both engine fuel control switches moved from RUN to CUTOFF in quick succession just after takeoff, resulting in dual engine power loss.
That incident triggered extensive regulatory scrutiny. In July 2025, Air India announced it had completed precautionary inspections of the fuel control switch locking mechanism on all Boeing 787-8 aircraft and found no defects at the time.
Following the recent pilot report, Air India has begun focused inspections of fuel control switches across its Boeing Dreamliner fleet. According to an internal company communication seen by Reuters, these checks have so far not identified a systemic issue with other aircraft. Air India has reiterated that passenger and crew safety remains its top priority. Boeing has said it is assisting with the review.
