Fuel control switches on grounded Air India Dreamliner found satisfactory after checks: Aviation Ministry
The Aviation Ministry on Tuesday said inspections of the fuel control switches on a grounded Air India Boeing 787 Dreamliner found both switches to be “satisfactory,” following a pilot’s report that one switch did not remain positively latched in the ‘RUN’ position during engine start.
In a statement, the ministry said Air India’s engineering team conducted the checks in line with procedures recommended by aircraft manufacturer Boeing and in the presence of officials from the Directorate General of Civil Aviation (DGCA).
According to the findings, both the left and right fuel control switches were found fully serviceable, with the locking tooth or pawl properly seated and not slipping from ‘RUN’ to ‘CUTOFF’ when force was applied parallel to the base plate.
However, engineers noted that the switch could move from ‘RUN’ to ‘CUTOFF’ if external force was applied in an incorrect direction, owing to the angular design of the base plate.
The ministry said this highlighted the importance of correct handling of the fuel control switch. The DGCA also cautioned that improper operation could cause the switch to slip between positions.
Engineers additionally checked the pull-to-unlock force of the fuel control switch on the affected aircraft, a replacement unit, and another aircraft, using Boeing’s prescribed procedures.
In all cases, the force required was found to be within specified limits. These inspections were carried out under DGCA supervision.
The regulator also reviewed a video circulating on social media that allegedly showed a defect in the fuel control switch. After analysis, the DGCA said the method demonstrated in the video did not follow Boeing’s recommended procedures.
The incident occurred on Air India flight AI-132, a Boeing 787-8 aircraft registered VT-ANX, operating from London to Bengaluru on February 1.
During engine start in London, the crew observed on two occasions that the fuel control switch did not remain positively latched when light vertical pressure was applied.
On the third attempt, the switch latched correctly and remained stable.
The crew carried out a physical verification to ensure the switch was fully latched in the ‘RUN’ position before continuing the flight.
No abnormal engine parameters, cautions or warnings were observed during the flight, which landed safely in Bengaluru.
After landing, the crew reported the issue in the aircraft’s post-flight defect log, following which Air India grounded the aircraft and referred the matter to Boeing. The airline informed the DGCA, while Boeing said it was in contact with Air India and was supporting the review.
The issue has drawn attention in the wake of the June 2025 crash of an Air India Dreamliner in Ahmedabad, in which investigators found that the aircraft’s engine fuel control switches had moved from ‘RUN’ to ‘CUTOFF’ shortly after take-off, killing 260 people.
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