DGCA orders fuel control switch inspections on various Boeing aircraft by July 21

By | July 15, 2025
DGCA fuel switch Boeing inspection after Air India crash

India’s aviation regulator, the Directorate General of Civil Aviation (DGCA), has taken firm action to ensure safety. On July 13, 2025, it ordered all Indian carriers to inspect fuel control switch locking mechanisms on Boeing 737 and 787 aircraft. Airlines must complete the checks by July 21.

This order follows a fatal crash involving an Air India Dreamliner in June.

What Sparked the Emergency Checks?

On June 12, 2025, Air India Flight 171 crashed shortly after taking off from Delhi. The aircraft, a Boeing 787-8, suffered dual engine failure just seconds into the flight.

Investigators found that both engine fuel control switches moved from RUN to CUTOFF moments after takeoff. This switch movement cut off the engines and led to the crash, killing all 133 people on board.

This disturbing detail led authorities to examine whether the locking mechanism on those switches had failed.

The FAA Issued a Warning in 2018

Concerns about these fuel control switches are not new. In December 2018, the US Federal Aviation Administration (FAA) released a Special Airworthiness Information Bulletin (SAIB). It warned operators that the lock on some Honeywell-made fuel switches could disengage without lifting the safety tab.

While the FAA did not label it an urgent safety threat, the advisory encouraged airlines to inspect the mechanism. Most ignored it at the time. The bulletin gained fresh attention only after the recent crash in India.

DGCA’s Inspection Order: What It Requires

The DGCA’s July 13 directive includes clear steps for airlines:

  • Aircraft under inspection: All Boeing 737 and 787 models operated by Indian carriers like Air India, IndiGo, Akasa Air, Air India Express, and SpiceJet. Boeing 777s are not part of the order.
  • Deadline: Airlines must finish all inspections by July 21, 2025.
  • Test method: Engineers must try to move the fuel switch between RUN and CUTOFF without lifting the guard. If the switch moves freely, the lock isn’t working and must be replaced.
  • Compliance report: Airlines need to submit results to the DGCA’s regional offices before the deadline.

DGCA clarified that this is not an airworthiness directive. However, it is a mandatory safety step given the recent crash.

Airlines Begin Checks on Priority

Indian airlines started acting even before the DGCA set the deadline. According to Air India, its teams have already checked over 60% of the 787 fleet. No major faults have surfaced so far.

An IndiGo official said, “We treat this as a serious issue. Even if just one switch fails, we can’t ignore the risk.”

SpiceJet and Akasa Air also confirmed that their checks are underway and on schedule.

Boeing and FAA Maintain Confidence in Safety

Boeing responded to the inspection order, stating that it stands by the safety of its aircraft. “We are working closely with our customers and Indian regulators,” a company spokesperson said.

The FAA has not issued a new directive. However, it stated that it continues to monitor developments worldwide.

Global Airlines Take Precaution

DGCA’s move has had a ripple effect. Airlines in South Korea, Singapore, and the UAE are also inspecting their Boeing jets.

Etihad Airways and Singapore Airlines have confirmed that they are checking their 787 fleets. These actions show that airlines are prioritizing preventive safety measures even without regulatory pressure.

Minimal Impact on Flyers

The inspections do not require long maintenance hours. Airlines can carry them out during routine ground checks.

Some flights may be adjusted or rescheduled. However, passengers are unlikely to face widespread delays or cancellations.

Travelers have reacted positively to DGCA’s proactive move. “I feel safer knowing these checks are happening. At least the regulator is not waiting for another accident,” said a passenger from Mumbai.

Final Word: Vigilance Saves Lives

The DGCA’s swift response after the Air India crash shows the importance of constant vigilance in aviation.

A fuel switch might seem like a minor part. But when two such switches shut off midair, they can bring down a jetliner.

By acting before another tragedy happens, India’s aviation authority has shown that safety must never wait.

Airlines now have just a few days left to finish inspections. What they find—and how fast they act—will say a lot about the industry’s commitment to saving lives.