‘No issues found’: Air India completes fuel control switch inspection in all Boeing 787, 737 aircraft
Air India has completed safety inspections on all its Boeing 787 and 737 aircraft. These checks focused on fuel control switch mechanisms. The move followed the crash of Flight AI 171 in June 2025, which raised serious safety concerns.
The airline reported that it found no mechanical issues during the inspections. The checks were done in line with a directive from the Directorate General of Civil Aviation (DGCA). The DGCA issued this order after a preliminary report hinted that the fuel control switches might have played a role in the AI 171 crash.
Why the Inspections Were Ordered
On June 12, Air India Flight AI 171, a Boeing 787-8, crashed just after takeoff. Investigators found that both engines lost thrust. The preliminary report suggested the fuel control switches might have moved to “CUTOFF”—which cuts fuel supply—while the plane was still in flight.
It’s still unclear whether the switches were moved by the pilot, due to a system failure, or by accident. The Aircraft Accident Investigation Bureau (AAIB) is leading the investigation. While the final report is pending, the DGCA ordered inspections of all similar aircraft operated by Indian airlines.
What Air India Did
Air India acted fast. It started inspections immediately after the DGCA directive on July 12. The airline checked all Boeing 787 Dreamliners and Boeing 737s, including those operated by Air India Express. All checks were completed before the July 21 deadline.
The airline confirmed that none of its aircraft had any faults. Every fuel control switch worked as designed. Locking mechanisms functioned correctly, with no signs of loose or faulty components.
In a statement, the airline said, “We completed all mandated inspections. All fuel switches were found to be secure and in working order.”
This quick and thorough response from Air India shows its focus on safety and transparency.
Global Airlines Also Respond
Other airlines around the world also took notice. Carriers like Emirates, Etihad, Singapore Airlines, and Scoot reportedly conducted their own inspections. Even though Boeing had not issued a new safety notice, the industry responded cautiously.
The U.S. Federal Aviation Administration (FAA) had raised concerns about this issue back in 2018. The FAA warned that the fuel control switches could be accidentally moved during flight if not properly secured. It advised airlines to inspect the locking mechanism and train pilots accordingly.
Air India’s recent inspections followed those earlier FAA guidelines. Although the switches passed all tests, the incident reminded airlines that even small parts can create major risks.
Safety Experts Weigh In
Experts say this type of mechanical issue—though rare—can have serious consequences. Capt. Neel Shah, a senior aviation safety consultant, explained:
“Sometimes it’s not a system failure. It’s about design choices. If a fuel switch is easy to move without a strong lock, that’s a risk. Small errors can lead to tragic outcomes.”
Analysts say the crash investigation might push aircraft manufacturers to redesign sensitive controls in the cockpit. Changes could include stronger locking mechanisms or safer switch placements.
What Comes Next
The AAIB will release a full report on the AI 171 crash within a year. This report will confirm whether the fuel switches caused the engine shutdowns—or if another issue was responsible.
Until then, the aviation industry remains cautious. Regulators in India and abroad are likely to review safety procedures more often. Airlines may also increase crew training to prevent accidental switch movements.
Air India’s Clean Record Offers Some Relief
Despite the tragedy, Air India’s prompt action offers some relief. The airline showed responsibility and transparency by completing inspections early. It communicated results clearly and addressed public concerns.
Air India also said it remains committed to assisting investigators. The airline will apply any changes or safety upgrades recommended by the AAIB or DGCA.
A spokesperson said, “Passenger safety is our top priority. We are fully cooperating with the investigation.”
Final Thoughts
Air India passed a major test of safety and leadership. Its Boeing 787 and 737 fleets are safe to operate, according to the latest checks. But this episode highlights how even small components—like a fuel switch—can raise life-threatening risks.
The aviation industry must continue improving. Stronger checks, better cockpit designs, and swift action after incidents are all crucial. Air India’s clean report is a step in the right direction. Still, the real answers will come when the AAIB completes its investigation.
Until then, both passengers and pilots must remain alert. In aviation, safety is never guaranteed—it’s earned every day, on every flight.
