CHENNAI: Air India has begun precautionary inspections of the fuel control switches on its Boeing 787 Dreamliner fleet after a malfunction was reported on an aircraft that operated a London Heathrow–Bengaluru flight on February 1, 2026, in the latest development to renew focus on the safety of a critical cockpit component.
The malfunction has revived scrutiny of the June 2025 Ahmedabad crash of Air India 787 Dreamliner, in which investigators found that both engine fuel control switches had moved to the cutoff position shortly after takeoff, leading to a catastrophic loss of thrust. That unresolved finding is again in focus as authorities examine whether a common mechanical or design vulnerability could link the two incidents.
According to reports on the Bangalore incident, the issue was flagged by the flight crew during post-landing checks, after the left engine fuel control switch on a Boeing 787-8 aircraft did not remain firmly locked in the “run” position and appeared to move toward “cutoff” during engine start. While the aircraft completed the flight safely and there was no impact on passengers, Air India grounded the plane as a precaution and informed the Directorate General of Civil Aviation (DGCA) and aircraft manufacturer Boeing.
The airline has since initiated fleet-wide inspections of fuel control switches across its Dreamliner aircraft. Internal assessments so far have not identified similar defects on planes already checked, and operations have continued normally, with only the affected aircraft remaining out of service pending detailed examination.
Fuel control switches regulate the flow of fuel to an aircraft’s engines and are among the most critical controls on the flight deck. Any uncommanded movement toward the cutoff position can lead to an immediate loss of thrust on the affected engine, making the integrity of the switch and its locking mechanism essential, particularly during start-up, takeoff and climb.
The latest report has drawn added scrutiny because of heightened sensitivity around fuel control switch behaviour following a fatal Air India crash near Ahmedabad in June last year, in which investigators found that both engine fuel switches had moved to cutoff shortly after takeoff. In the aftermath of that accident, Indian aviation authorities had directed operators to carry out checks of the switch mechanisms on relevant aircraft types, including the Boeing 787, and Air India had reported at the time that no abnormalities were detected.
That a new anomaly has now been reported, despite earlier inspections, raises questions about whether existing checks are sufficient to detect subtle mechanical wear, latch degradation or intermittent faults that may not be apparent during routine examinations. Aviation safety specialists note that while these switches are designed to require deliberate pilot action, ageing components, repeated use and manufacturing tolerances can, over time, affect how securely they lock into position.
From a regulatory standpoint, the DGCA is expected to closely monitor Air India’s inspection programme and may seek additional data from Boeing on the design, service history and any known reliability trends associated with the switch assemblies. Depending on findings, the matter could lead to updated maintenance guidance, more frequent inspections or, in the longer term, design modifications.
For Air India, which is in the midst of a wide-ranging fleet renewal and transformation programme, the episode underscores the operational and reputational importance of proactive safety management. By grounding the affected aircraft and launching fleet-wide checks without waiting for a directive, the airline has signalled an intent to err on the side of caution.
At present, there is no indication of widespread defects across the Dreamliner fleet, and the airline has not announced any cancellations or large-scale disruptions linked to the inspections. However, the incident is likely to keep attention firmly on the reliability of cockpit control systems and the robustness of inspection regimes, not just in India but across the global aviation industry.
Meanwhile, a note from the ministry of civil aviation Tuesday afternoon said; "During engine start in London, on two occasions crew observed that the fuel control switch did not remain positively latched in the “RUN” position when light vertical pressure was applied. On the third attempt, the switch latched correctly in “RUN” and subsequently remained stable. Before continuing with the rest of procedure, a physical verification was performed by the crew to confirm that the switch was fully and positively latched in the “RUN” position. No abnormal engine parameters, cautions, warnings, or related system messages were observed during engine start or at any time thereafter. The operating crew member was briefed on the observation, unnecessary contact with the switch was avoided, and engine indications and alerting systems were closely monitored by the crew for the remainder of the flight. The flight was completed without incident."
The ministry added that after landing at Bangalore, crew reported the defect in the PDR. Air India referred the matter to Boeing for further guidance. Based on the Boeing recommended checks to establish the serviceability of fuel control switch, Air India engineering observed that:
“Both left and right switches were checked and found satisfactory, with the locking tooth/pawl fully seated and not slipping from RUN to CUTOFF. When full force was applied parallel to the base plate, the switch remained secure. However, applying external force in an incorrect direction caused the switch to move easily from RUN to CUTOFF, due to the angular base plate allowing slip when pressed improperly with finger or thumb.”
In addition, based on Boeing’s communication, the pull-to-unlock force was checked on the fuel control switch using the recommended procedure on the involved fuel cut off switch, the fuel control unit to be installed and fuel cut off switch of another aircraft. In all cases the pull-to-unlock force was found within limits. These inspections were carried out in the presence of DGCA officers, the ministry said.
As investigators and engineers work to determine whether the London–Bengaluru aircraft’s issue points to an isolated mechanical fault or a broader pattern, the episode serves as a reminder that even small components can have outsized safety implications, and that continuous vigilance remains central to modern airline operations.