Air India Grounds Boeing Dreamliner After Pilot Flags Possible Fuel Control Switch Defect

Air India has grounded one of its Boeing 787‑8 Dreamliner aircraft after a pilot reported a potential defect involving the aircraft’s fuel control switch, a critical component in engine operation. The development comes amid renewed global scrutiny of the Boeing 787’s safety systems, particularly the fuel switch mechanism that was central to a tragic crash in 2025 that claimed 260 lives in India.

Reuters +1

The incident occurred on February 2, 2026, following the aircraft’s arrival from London Heathrow to Bengaluru. According to multiple sources, the crew reported that the fuel control switch on the left engine failed to stay in the “RUN” position during engine startup, slipping instead toward “CUTOFF” — a position that cuts off fuel to the engine. This was noted during two separate start‑up attempts, prompting the pilot to raise safety concerns to airline operations.

The Times of India

In response, Air India immediately grounded the Boeing 787‑8 jet (registration VT‑ANX) as a precautionary measure and notified India’s civil aviation regulator, the Directorate General of Civil Aviation (DGCA). A spokesperson for the airline said the matter had been communicated to regulators and that the company was involving Boeing — the original aircraft manufacturer — to assess the issue on a priority basis.

The New Indian Express

What Are Fuel Control Switches and Why They Matter

Fuel control switches are small but vital components in commercial aircraft. They regulate the flow of fuel to engines and are used to start or shut down engines on the ground. In rare circumstances, pilots may also operate these switches during flight for engine restart procedures following a failure. On the Boeing 787, each engine has its own switch, located just below the thrust levers in the cockpit.

Business Today

The switches have two positions — RUN and CUTOFF — and are designed to be spring‑loaded to prevent accidental movement. To change the position, a pilot must pull the switch up and then slide it deliberately between RUN and CUTOFF. If the switch is moved into the CUTOFF position, the associated engine will immediately lose fuel feed and begin to shut down.

Business Today

Because of this design, aviation experts have long regarded uncommanded movement of fuel control switches as highly unlikely, barring deliberate pilot action or significant mechanical or electrical failure.

Business Today

The Ghost of AI171: The 2025 Dreamliner Crash

The latest incident comes in the shadow of a deadly Boeing 787 crash on June 12, 2025, near Ahmedabad, Gujarat. That aircraft, operating as Air India Flight AI171, crashed moments after takeoff, killing 260 people on board and on the ground.

Forbes India

A preliminary investigation by India’s Aircraft Accident Investigation Bureau (AAIB) found that both engine fuel control switches on the ill‑fated aircraft shifted from RUN to CUTOFF within a second of one another shortly after lift‑off, cutting off fuel supply and cutting engine thrust. Cockpit voice recordings captured one pilot asking the other why the fuel had been cut off, to which the other responded that he had not done so.

Forbes India

The preliminary report did not establish whether the switches moved due to human action or a technical fault, but the unusual behavior of such a critical system immediately drew regulatory attention and industry concern.

Forbes India

Heightened Scrutiny and Precautionary Measures

Following the AI171 crash, India’s DGCA and Air India implemented inspections of fuel control switches across the airline’s entire Boeing 787 fleet. At the time, Air India reported no anomalies. However, the latest pilot report of a switch slipping toward CUTOFF — even before departure — has prompted further action.

The New Indian Express

According to internal communications from Air India’s senior vice president for flight operations, the airline has initiated a precautionary fleet‑wide re‑inspection of all fuel control switch mechanisms across its Boeing 787 aircraft. This effort is aimed at verifying the normal operation of the fuel control switch latch, even as Boeing evaluates the reported defect firsthand.

The Times of India

Air India operates 33 Boeing 787 aircraft, including 26 Boeing 787‑8 and 7 Boeing 787‑9 jets. The inspections are reported to be partially complete, with no irregularities found so far on the aircraft checked.

www.ndtv.com

Boeing’s Role and Industry Response

Boeing has confirmed that it is in contact with Air India and supporting the airline’s review of the reported switch issue. While OEM (original equipment manufacturer) involvement is standard procedure in technical assessments of this nature, the spotlight on the 787’s fuel control system has only intensified due to its suspected link to the previous crash.

Reuters

The incident highlights broader safety discussions in the aviation sector regarding the interaction between cockpit controls, mechanical components, and accident causation. Aviation safety organizations are calling for transparent reporting and thorough investigation of such malfunctions, noting that understanding whether a defect is mechanical, electrical, or procedural is critical to restoring public confidence.

ETInfra.com

Public and Regulatory Implications

As news of the grounding spreads, there are concerns among aviation analysts and passenger safety advocates that even minor technical anomalies could have outsized implications for aircraft operations and regulatory oversight. The DGCA will likely play a central role in determining the severity and scope of any safety advisories or mandates that may follow.

ETInfra.com

For Air India, the incident is a reminder that heightened vigilance remains crucial in post‑accident environments, especially when dealing with critical flight control systems. The airline has emphasized that passenger safety remains its top priority, assuring the public that the matter is being addressed at the highest operational levels.

The New Indian Express

Looking Ahead

While the grounded Dreamliner and ongoing inspections do not currently point to widespread defects across the fleet, aviation safety investigators — including the DGCA and independent watchdogs — will be closely monitoring the findings. Any confirmed technical issue with fuel control switches could prompt revised maintenance protocols, regulatory advisories, or even design reviews for Boeing 787 aircraft worldwide.

In the meantime, industry observers note that such precautionary actions, while disruptive, play an essential role in maintaining confidence in air travel and advancing safety standards across global aviation.

The Times of India