Air India Boeing 787 Technical Issues

Reference TimelineLast updated APR 7
SUMMARY

The Directorate General of Civil Aviation (DGCA) clarified on April 7, 2026, that a recent fuel switch issue on an Air India Boeing 787 was due to incorrect crew handling, not a mechanical fault, advising Air India to share Boeing's operating procedures with its crews. As of April 7, 2026: The DGCA has ruled out a systemic defect in Boeing 787 fuel control switches, despite a previous grounding and an Air India Boeing 787-8 diverting to Jeddah on March 25, 2026, due to multiple system warnings. India's civil aviation regulator initiated enforcement proceedings against Air India in February 2026 due to a fourfold increase in technical defects, reaching 1.09 per 1,000 flights in January 2026. Air India had previously initiated a fleet-wide inspection of fuel control switches on its Boeing 787-8 Dreamliner fleet in February 2026.

Timeline

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April 2026 — 1 developments

  1. The Directorate General of Civil Aviation (DGCA) clarified that a recent fuel switch issue on an Air India Boeing 787 was due to incorrect crew handling, not a mechanical fault.

    The Directorate General of Civil Aviation (DGCA) clarified that a recent fuel switch issue on an Air India Boeing 787 was due to incorrect crew handling, not a mechanical fault. The regulator stated the switch did not latch correctly on the first attempt but functioned properly on a subsequent try. Air India has been advised to share Boeing's operating procedures for the fuel cut-off switch with its crews.

March 2026 — 1 developments

  1. An Air India Boeing 787-8 diverted to Jeddah on March 25, 2026, due to multiple system warnings, inc…

    An Air India Boeing 787-8 diverted to Jeddah on March 25, 2026, due to multiple system warnings, including auto-throttle disconnect and fuel jettison system fault, on a flight from Bengaluru to London. The aircraft had previously been under scrutiny, with the DGCA issuing a show-cause notice for operating it despite repetitive faults.

February 2026 — 12 developments

  1. India's civil aviation regulator has initiated enforcement proceedings against Air India following a substantial increase in technical defects across its Boeing 787 fleet.

    India's civil aviation regulator has initiated enforcement proceedings against Air India following a substantial increase in technical defects across its Boeing 787 fleet. In January 2026, the airline reported 1.09 technical defects per 1,000 flights, a fourfold increase from the previous month, with overall technical incidents reaching a 14-month high. This action comes after a specific incident involving a potential fuel control switch defect led to an aircraft grounding.

  2. India's civil aviation regulator has cleared the design of fuel control switches on Boeing 787 Dreamliners, ruling out a systemic defect.

    India's civil aviation regulator has cleared the design of fuel control switches on Boeing 787 Dreamliners, ruling out a systemic defect. This decision concludes the investigation into the Air India flight that was grounded in Bengaluru after a pilot reported an issue with a fuel control switch during a flight from London.

  3. Air India is investigating whether its crew followed all required procedures after a Boeing aircraft…

    Air India is investigating whether its crew followed all required procedures after a Boeing aircraft departed from London with a potential fuel-switch defect before being grounded in India. Britain's aviation watchdog has requested a comprehensive root-cause analysis and a preventative plan.

  4. India's aviation regulator is advising Air India to circulate recommended Boeing procedures for operating fuel cut-off switches on the 787.

    India's aviation regulator is advising Air India to circulate recommended Boeing procedures for operating fuel cut-off switches on the 787. This follows concerns raised by the crew during a London Heathrow-Bengaluru service on February 1st, where the crew observed that one of the fuel-control switches did not operate correctly. The regulator's advice is a new step in addressing the potential defect.

  5. The DGCA advised Air India to reinforce Boeing-recommended procedures for the operation of the fuel 'CUT OFF' switch to its crew members.

    The DGCA advised Air India to reinforce Boeing-recommended procedures for the operation of the fuel 'CUT OFF' switch to its crew members.

  6. Boeing confirmed it was in contact with Air India and supporting their review of the matter concerning the fuel control switch defect.

    Boeing confirmed it was in contact with Air India and supporting their review of the matter concerning the fuel control switch defect.

  7. Air India initiated a precautionary fleet-wide inspection of fuel control switches on its Boeing 787-8 Dreamliner fleet.

    Air India initiated a precautionary fleet-wide inspection of fuel control switches on its Boeing 787-8 Dreamliner fleet. The airline stated that engineering had escalated the matter to Boeing for priority evaluation and that the impacted Fuel Control Switch module would be sent to the OEM for further checks.

  8. The DGCA stated that the fuel control switches on the grounded aircraft were checked and found to be satisfactory, with no abnormal engine parameters observed during the flight.

    The DGCA stated that the fuel control switches on the grounded aircraft were checked and found to be satisfactory, with no abnormal engine parameters observed during the flight. The regulator also noted that Boeing had confirmed the switches' pull-to-unlock force was within limits.

  9. Air India grounded a Boeing 787-8 aircraft on February 2, 2026, after a pilot reported a defect with the left engine's fuel control switch.

    Air India grounded a Boeing 787-8 aircraft on February 2, 2026, after a pilot reported a defect with the left engine's fuel control switch. The switch reportedly failed to remain locked in the 'RUN' position during engine start-up, moving towards 'CUTOFF', a malfunction that could lead to inadvertent engine shutdown. This issue is concerning as it mirrors a risk previously identified in relation to a past crash.

  10. Air India has grounded one of its Boeing 787-8 Dreamliner aircraft after a pilot reported that a fuel cut-off switch failed to remain in the RUN position and moved towards CUTOFF.

    Air India has grounded one of its Boeing 787-8 Dreamliner aircraft after a pilot reported that a fuel cut-off switch failed to remain in the RUN position and moved towards CUTOFF. The incident occurred as the aircraft was preparing to depart from London Heathrow Airport bound for Bengaluru. The airline has initiated a precautionary fleet-wide inspection.

  11. Air India confirmed that the aircraft involved in the February 1 incident was grounded in Bengaluru after landing.

    Air India confirmed that the aircraft involved in the February 1 incident was grounded in Bengaluru after landing. The airline informed Boeing and India's Directorate General of Civil Aviation (DGCA) about the reported defect.

  12. An Air India Boeing 787-8 Dreamliner (AI132) operating from London to Bengaluru experienced an issue…

    An Air India Boeing 787-8 Dreamliner (AI132) operating from London to Bengaluru experienced an issue during engine start-up where the left fuel control switch reportedly slipped from the 'RUN' to 'CUTOFF' position and did not lock. The issue was resolved on the third attempt, and the flight proceeded to Bengaluru.

January 2026 — 1 developments

  1. A source indicated that the AAIB investigation into the Air India Flight 171 crash was examining var…

    A source indicated that the AAIB investigation into the Air India Flight 171 crash was examining various aspects, including technical, operational, organizational, and human factors, with nothing ruled out. The probe was reportedly leaning towards deliberate pilot action as a possible cause.

July 2025 — 1 developments

  1. India's Aircraft Accident Investigation Bureau (AAIB) released a preliminary report on the Air India…

    India's Aircraft Accident Investigation Bureau (AAIB) released a preliminary report on the Air India Flight 171 crash, stating that fuel supply to both engines was cut off within a second of takeoff.

June 2025 — 1 developments

  1. Air India Flight 171, a Boeing 787-8 Dreamliner, crashed shortly after takeoff from Ahmedabad, India, killing 241 of the 242 people on board, plus 19 on the ground.

    Air India Flight 171, a Boeing 787-8 Dreamliner, crashed shortly after takeoff from Ahmedabad, India, killing 241 of the 242 people on board, plus 19 on the ground. The preliminary investigation indicated that the fuel-control switches in the cockpit moved from the 'run' to the 'cutoff' position, causing both engines to shut down.

January 2018 — 1 developments

  1. The US Federal Aviation Administration (FAA) issued a Safety Alert for Operators (SAIB NM-18-33) war…

    The US Federal Aviation Administration (FAA) issued a Safety Alert for Operators (SAIB NM-18-33) warning that certain fuel control switches, including those on Boeing 787s, could malfunction, increasing the risk of accidental engine shutdown.