DGCA orders Indian airlines to inspect Boeing aircraft fuel switch systems by July 21 after AI171 crash. FAA had flagged the issue in 2018. Get full details here.
Fuel Switch Inspection: In a decisive move to enhance flight safety, the Directorate General of Civil Aviation (DGCA) has directed all Indian airline operators to conduct mandatory inspections of the fuel control switch locking system in Boeing aircraft. The directive comes in the wake of the tragic crash of Air India Flight AI171, which claimed the lives of 260 individuals, including all 241 passengers on board.
What Prompted the Inspection Order?
The inspection order follows preliminary findings from the Aircraft Accident Investigation Bureau (AAIB), which revealed that both engines of the ill-fated Boeing aircraft shut down unexpectedly shortly after takeoff from Ahmedabad. Investigators linked the issue to potential disengagement of the fuel control switch locking mechanism, a problem that had been previously flagged by the US Federal Aviation Administration (FAA) in 2018.
Back in June, The Tribune highlighted a seven-year-old FAA bulletin — Special Airworthiness Information Bulletin (SAIB NM-18-33) — which warned operators of possible failure in fuel control switches, particularly those bearing part number 4TL837-3D. These switches are commonly used in Boeing aircraft, including the 787 Dreamliner series operated by Air India.
Why Weren’t Earlier Warnings Acted Upon?
Despite the FAA bulletin clearly outlining the potential risk, Air India reportedly did not implement the recommended inspections, citing that the bulletin was advisory in nature and not classified as an Airworthiness Directive (AD). This classification allowed the airline to bypass the checks without violating regulatory compliance.
However, the recent crash has triggered a re-evaluation of such advisories. The DGCA stated that international operators have already begun voluntary checks, and therefore, it was imperative for India to mandate the same.
DGCA’s New Directive: What It Says
According to the official notice issued by R B Jamir, Director of Airworthiness, all Indian airlines operating affected Boeing aircraft are now required to complete inspections and submit compliance reports by July 21, 2025. The order clearly states:
“Strict adherence to the timeline is essential to ensure continued airworthiness and safety of operations.”
The DGCA’s directive applies to several Boeing models, including:
- Boeing 737
- Boeing 747
- Boeing 757
- Boeing 767
- Boeing 787
- McDonnell Douglas MD-11
- McDonnell Douglas MD-90
These models are widely used by major Indian airlines including Air India, IndiGo (for wet lease), Vistara, and SpiceJet.
What’s at Stake?
While the FAA advisory from 2018 was classified as non-mandatory, the fatal AI171 crash appears to have fundamentally shifted the approach of Indian aviation authorities. The new stance reflects a precautionary principle, prioritizing safety over procedural classifications.
The incident underscores a serious gap in how advisories are treated compared to mandatory directives. Aviation analysts argue that non-binding bulletins should no longer be taken lightly, especially when they concern vital aircraft systems such as engine fuel control mechanisms.
No Prior Defects Reported, Says Maintenance Log
Interestingly, the maintenance records of the crashed aircraft reportedly showed no history of issues with the fuel switch system, either before or after throttle control module replacements in 2019 and 2023. However, the failure still occurred, raising urgent questions about the long-term reliability of the component and the importance of proactive inspections.
Global Implications
The DGCA’s move is expected to influence other aviation regulators in Asia and globally, many of whom may now consider mandating similar inspections for Boeing aircraft within their jurisdictions. The spotlight is now back on aircraft manufacturers, airline maintenance teams, and regulatory bodies to ensure every potential safety risk is identified and mitigated before it turns catastrophic.
The DGCA’s inspection order is a critical step toward restoring public trust in aviation safety after the AI171 disaster. While the tragedy cannot be undone, stringent actions like these could prevent similar incidents in the future.
All eyes are now on Indian carriers to comply swiftly and thoroughly with the inspection deadline of July 21, as the aviation industry grapples with increasing scrutiny over aircraft reliability and regulatory oversight.