Air India Grounds Dreamliner After Fuel Control Switch Moves to ‘Cutoff’

An Air India Boeing 787 Dreamliner has been grounded after its left engine fuel control switch failed to remain in the ‘run’ position and shifted to ‘cutoff’ twice during engine start-up, the airline said on Monday.

The aircraft, operating flight AI 132 from London Heathrow to Bengaluru, was withdrawn from service following the pilot’s report.

“We are aware that one of our pilots has reported a possible defect on the fuel control switch of a Boeing 787-8 aircraft,” an Air India spokesperson said. “After receiving this information, the aircraft has been grounded and the original equipment manufacturer has been engaged to examine the issue on priority.”

Boeing said it was in contact with the airline and supporting its review. “We will defer to the customer,” a Boeing spokesperson said. The incident has been reported to the Directorate General of Civil Aviation (DGCA), Air India said.

The airline added that it had previously inspected fuel control switches across its entire Boeing 787 fleet following a DGCA directive and found no issues. “Safety of our passengers and crew remains our top priority,” the spokesperson said.

Heightened scrutiny of fuel switches

The development comes amid increased scrutiny of fuel control switches after the July 2025 Air India Dreamliner crash in Ahmedabad, which killed 260 people. A preliminary investigation report into that accident said both engine fuel control switches briefly moved from ‘run’ to ‘cutoff’ seconds after takeoff, cutting fuel supply and causing a loss of engine power.

Cockpit voice recordings captured one pilot asking the other why the fuel had been cut off, with the other responding that he had not done so. The switches were later returned to the ‘run’ position and were found set to ‘run’ at the crash site, investigators said. The report did not identify which remarks were made by the captain or the first officer.

How fuel control switches work

Fuel control switches regulate fuel flow to an aircraft’s engines and are primarily used to start or shut down engines on the ground, or to manually shut them down or restart them in the event of an in-flight failure.

On the Boeing 787, the two switches are located below the thrust levers and are spring-loaded to stay in position. To move a switch between ‘run’ and ‘cutoff’, a pilot must first pull it upward before shifting it, a design intended to prevent accidental movement.

Aviation experts say the switches are unlikely to be moved unintentionally. If shifted to ‘cutoff’, the effect is immediate, cutting fuel flow and engine power. When moved back to ‘run’ during flight, the engine control system automatically initiates a relight and thrust recovery sequence.

Current status

Air India said the aircraft will remain grounded until the issue is fully assessed in coordination with Boeing and the regulator.