In a significant update for aviation safety, Air India has announced that inspections of its Boeing 787-8 Dreamliner fleet’s fuel control switch locking mechanisms have been completed with no issues detected. The inspections were conducted over the past weekend following a directive from the Directorate General of Civil Aviation (DGCA) on July 14, 2025. This directive was issued in the wake of a preliminary report by the Aircraft Accident Investigation Bureau (AAIB) on the tragic Air India flight AI171 crash on June 12, which claimed 270 lives.
Background: The AI171 Crash and Regulatory Response
The AI171 crash near Ahmedabad drew global attention to the fuel control switch (FCS) locking mechanisms of Boeing aircraft. According to the AAIB’s preliminary report, both engine fuel control switches of the Boeing 787-8 moved from the ‘RUN’ to ‘CUTOFF’ position within a one-second interval shortly after takeoff. This led to a dual engine failure and a catastrophic loss of altitude, resulting in the aircraft crashing into a medical college hostel.
In the cockpit voice recordings recovered, one pilot is heard asking the other why the fuel switches were cut off, to which the second pilot responded that he did not take such an action. This sequence of events raised concerns over potential mechanical or systemic failures in the locking mechanism of the FCS, prompting the DGCA to mandate inspections for all Indian airlines operating Boeing 737 and 787 aircraft. As reported by NDTV Profit, the inspection deadline was set for July 21, 2025.
Air India’s Proactive Measures
In compliance with the DGCA’s directive, Air India initiated precautionary inspections over the weekend of July 15-16. According to an internal communication shared with pilots and reported by The Hindu, the airline’s engineering team conducted thorough checks on the locking mechanisms of the FCS across its entire Boeing 787 fleet. The inspections concluded without identifying any faults.
In addition to the inspections, Air India confirmed that all its Boeing 787-8 aircraft had previously undergone Throttle Control Module (TCM) replacements in accordance with Boeing’s maintenance schedule. The FCS is an integral part of this module, which regulates the flow of fuel to the engines. As noted by Aviation A2Z, similar module replacements were carried out in 2019 and 2023, further ensuring compliance with manufacturer and regulatory standards.
Industry-Wide Impact and International Response
The AAIB’s findings and the DGCA’s subsequent directive have had a ripple effect across the aviation industry. Other Indian carriers, including SpiceJet, Akasa Air, and IndiGo, have initiated inspections of their Boeing fleets. International airlines such as Singapore Airlines and Etihad Airways have also begun voluntary checks on their Boeing 787 aircraft, despite the absence of a mandatory directive from their respective regulators.
The U.S. Federal Aviation Administration (FAA) had previously issued an advisory in 2018 regarding potential disengagement issues with the locking mechanisms of fuel control switches on Boeing 737 aircraft. However, this advisory did not extend to Boeing 787 models. As reported by Business Standard, the FAA has reiterated that the issue does not pose an immediate safety risk and has not escalated the advisory to a mandatory airworthiness directive. Nonetheless, the renewed focus on the FCS design has prompted precautionary inspections worldwide.
Ensuring Future Safety
Air India has emphasized its commitment to maintaining the highest safety standards. In its internal message to pilots, the airline advised continued vigilance and adherence to the existing reporting process for any technical defects. Pilots were reminded to utilize tools like the Coruson reporting system to flag any operational concerns promptly.
While the AAIB’s preliminary report has not suggested immediate recommendations for Boeing or engine manufacturers, the investigation remains ongoing. The engines from the crashed AI171 flight have been quarantined for detailed examination, and fuel samples are under analysis. The final report is expected to shed more light on the sequence of events and any potential design flaws in the FCS locking mechanism.
The aviation industry will undoubtedly monitor these developments closely, as the findings could lead to broader implications for aircraft design, maintenance, and operational protocols globally.