Air India Grounds Dreamliner Over Fuel Switch Fears

On February 2, 2026, Air India made headlines when it grounded one of its Boeing 787-8 Dreamliner jets after a pilot reported unusual behavior involving a critical engine fuel control switch. The incident, which occurred during a scheduled London to Bengaluru flight, immediately drew attention—not just because it disrupted Air India’s operations, but because it echoed the circumstances surrounding last year’s devastating crash of Air India flight AI-171, which killed 260 people. With regulators, pilots, and safety advocates all weighing in, the story has become a focal point for global aviation safety discussions.

The aircraft in question, registered as VT-ANX, was nine years old and had completed its journey from London without incident. But the trouble began during engine start-up in London. According to the Directorate General of Civil Aviation (DGCA) and reporting by BBC, the crew noticed that the left engine fuel control switch didn’t stay firmly latched in the RUN position when light vertical pressure was applied. On two separate attempts, the switch moved toward the CUTOFF position—a transition that, under certain conditions, could shut down an engine in flight. On the third try, the switch remained stable, and the crew monitored the system closely for the duration of the flight.

Air India acted quickly. The airline grounded the Dreamliner immediately upon arrival in Bengaluru and notified India’s aviation regulator, the DGCA. As an Air India spokesperson explained, “We are aware that one of our pilots has reported a possible defect on the fuel control switch of a Boeing 787-8 aircraft. After receiving this initial information, we have grounded the aircraft and are involving the OEM to get the pilot’s concerns checked on a priority basis. The matter has been communicated to the aviation regulator, DGCA.” Boeing, the plane’s manufacturer, confirmed its support for Air India’s investigation, telling BBC, “We are in contact with Air India and are supporting their review of this matter.”

Fuel control switches are no ordinary cockpit gadget. They regulate the flow of fuel to an aircraft’s engines, allowing pilots to start, shut down, or restart engines both on the ground and in flight. On the Boeing 787, these switches are spring-loaded and designed to stay locked in either the RUN or CUTOFF position—preventing accidental movement. In order to move the switch, a pilot must pull it upward before toggling between modes. The integrity of this locking mechanism is crucial: a malfunction could, in a worst-case scenario, lead to an inadvertent engine shutdown.

This is not the first time Air India has scrutinized its Dreamliner fleet over this very issue. The June 2025 crash of flight AI-171, also a Boeing 787-8, remains fresh in the industry’s memory. According to the Aircraft Accident Investigation Bureau’s (AAIB) preliminary report, both engine fuel control switches on the ill-fated flight transitioned from RUN to CUTOFF within a second of each other moments after takeoff from Ahmedabad. The engines lost thrust, and the aircraft crashed, claiming 260 lives. The AAIB’s report, released in July 2025, did not determine whether the switches were physically moved by the pilots, triggered by a mechanical fault, or caused by an electrical or software glitch. Cockpit voice recordings revealed confusion: one pilot asked the other why the fuel had been cut off, only to be told, “I did not.”

Following the AI-171 disaster, the DGCA ordered inspections of fuel control switches on all Boeing 787 and 737 aircraft operating in India. Air India, for its part, reported that it had checked the switches across its Dreamliner fleet and found no issues. The airline reiterated this position after the most recent incident: “Air India had checked the fuel control switches on all Boeing 787 aircraft in its fleet after a directive from the DGCA, and had found no issues,” the spokesperson said.

The DGCA moved swiftly after the VT-ANX event. On February 3, 2026, the regulator inspected the grounded Dreamliner’s fuel control switches, as well as those on another aircraft. According to the DGCA, when operated according to Boeing’s recommended procedure, the switches stayed firmly in the RUN position. However, the regulator noted, “incorrect handling” could cause the switch to move easily from RUN to CUTOFF. The DGCA instructed Air India to circulate Boeing’s operating procedures to all crew members, emphasizing the need for careful handling. The flight in question, it’s worth noting, was completed safely, and no passengers were ever at risk.

Industry experts have weighed in on the technical side. Aviation consultant and former air accident investigator Tim Atkinson told BBC, “These switches are designed with one purpose in mind, and that is that they cannot be moved unintentionally. There is no doubt in my mind that the design is good. I would be astonished to find it had some kind of latent defect.” Still, the issue has prompted fresh calls for vigilance. The Safety Matters Foundation, an aviation safety advocacy group, called for “immediate and transparent disclosure” from Air India and the DGCA regarding the findings from the inspection, as well as a regulatory review of precautionary checks. “What makes this event deeply troubling is not only that it happened, but that it occurred after Air India publicly stated it had conducted precautionary checks across its 787 fleet and found no issues,” said Capt. Amit Singh, founder of the Foundation.

The Federation of Indian Pilots (FIP) has also pressed for more comprehensive checks of Boeing 787 electrical systems, raising the possibility that the fuel control switches could have been affected by electrical malfunctions. “From day one after the AI-171 crash, we have been insisting on checking all B787s for their electrical systems,” said FIP president CS Randhawa. The FIP cited previous global incidents, such as a 2019 emergency involving an All Nippon Airways Boeing 787-8, as evidence that the Dreamliner’s systems deserve closer scrutiny.

Adding to the complexity, the US Federal Aviation Administration (FAA) had issued a safety alert for operators in 2018, warning of the potential disengagement of the fuel control switch locking feature on certain Boeing aircraft, including the 787. The alert was advisory, not mandatory, and did not result in an airworthiness directive. Many airlines, including Air India, had not conducted the recommended checks at the time. Only after the 2025 crash did India’s DGCA insist on fleet-wide inspections.

The regulatory and technical questions are being debated against a backdrop of commercial developments. Just days before the latest incident, Air India announced an expansion of its relationship with Boeing, placing an order for 30 more Boeing 737 aircraft and entering into a long-term component services agreement for its Dreamliner fleet. While business continues, the airline’s leadership insists that “the safety of our passengers and crew remains top priority.”

As the investigation into the AI-171 crash continues, with a final report expected in the coming months, the aviation world is watching closely. For now, the recent scare appears to have been the result of either handling technique or an isolated quirk, rather than a systemic defect. But with lives at stake and memories of last year’s tragedy still raw, every detail—and every switch—matters.