Air India has completed inspections of the fuel control switch (FCS) locking mechanisms on its Boeing 787 and 737 aircraft fleets, finding no issues. This was in compliance with a directive from the Directorate General of Civil Aviation (DGCA) issued on July 14, 2025. The directive followed the tragic crash of a Boeing 787 in Ahmedabad last month, which killed 260 people.

The inspections were initiated voluntarily by Air India on July 12, 2025, before the DGCA directive. Air India voluntarily started the inspections on July 12 and completed them within the time limit set by the DGCA. The airline has communicated the results to the regulator.

The DGCA's order to inspect the fuel switch locking systems on Boeing 787 and 737 aircraft by July 21 came after the Aircraft Accident Investigation Bureau (AAIB) preliminary report indicated that the fuel switches were cut off before the Air India crash. Air India flight AI 171, a Boeing 787-8 en route to London Gatwick, crashed shortly after takeoff from Ahmedabad on June 12, 2025, killing 241 of the 242 people onboard and 19 people on the ground.

The AAIB preliminary report stated that the fuel supply to both engines of the plane was cut off within one second, causing confusion in the cockpit soon after takeoff. Cockpit voice recordings revealed one pilot questioning the other about the fuel cutoff, with both denying responsibility. The AAIB expects to release its final report within a year.

The US Federal Aviation Administration (FAA) had flagged concerns in 2018 about the potential disengagement of the fuel control switch locking feature on certain Boeing aircraft models, including the 787s and 737s. This was noted in a Special Airworthiness Information Bulletin (SAIB), but no airworthiness directive was issued because the matter was not classified as a safety concern. The SAIB advised operators of various Boeing models to inspect the switches.

The fuel control switches are critical components that manage fuel flow to aircraft engines, allowing pilots to start or shut them down, or manually intervene during in-flight engine failures. The switches are designed with a locking mechanism to prevent accidental movement. The switches have a spring-loaded feature and brackets on either side to protect them. The locking mechanism requires pilots to lift the switch before moving it between the 'RUN' and 'CUTOFF' positions.

Air India operates a fleet of 33 Boeing 787s, while its low-cost subsidiary Air India Express operates 75 Boeing 737s. Other domestic carriers, including IndiGo, SpiceJet, and Akasa Air, also operate these types of aircraft. IndiGo operates seven B737 Max 8 and one B787-9.

Following the AI 171 crash, some foreign carriers, including Abu Dhabi-based Etihad, have begun voluntary checks of the fuel control switches on their 787 fleets. However, the FAA and Boeing have notified operators of 787 jets that the fuel switch locks on the aircraft are safe and no further action is needed.