Air India has completed precautionary inspections on the fuel control switch (FCS) locking mechanisms of all its Boeing 737 aircraft, the airline announced on Tuesday, reporting that no defects were found during the checks. The move follows similar inspections on its Boeing 787 Dreamliner fleet, which also yielded no issues.
The checks come in the wake of an ongoing investigation into a recent Air India crash involving a Boeing 787 jet that claimed the lives of 241 passengers and crew, along with 19 people on the ground. The focus of the probe has turned to the aircraft’s FCS, a critical component responsible for regulating fuel flow to the engines.
According to preliminary findings, confusion in the cockpit preceded the fatal incident, with investigators pointing to a near-simultaneous flipping of the plane’s engine fuel cutoff switches, which resulted in a sudden loss of power. Experts say the FCS is designed with safety measures to prevent accidental operation, making the malfunction particularly concerning.
The switches are spring-loaded and require deliberate action to change position: pilots must pull them upward before toggling between “run” and “cutoff” modes. Each switch has independent wiring and power systems to avoid simultaneous failure, according to aviation safety analyst John Cox.
Air India, which operates the wide-body Boeing 787s for long-haul international routes, emphasized that it is cooperating fully with investigators and regulatory authorities. The airline reiterated its commitment to operational safety and regulatory compliance across its fleet.
Its low-cost subsidiary, Air India Express, operates the Boeing 737 fleet, which also underwent the same precautionary checks. All inspections across both aircraft types have now been completed, with no mechanical anomalies discovered in the FCS systems.
The final accident report is expected within a year, but the focus on fuel control mechanisms has already prompted increased scrutiny from global aviation authorities and airlines operating similar aircraft.
“As a responsible carrier, we are fully aligned with global best practices in aviation safety,” Air India said in a statement. “The proactive inspections reaffirm our unwavering commitment to safeguarding passengers and crew.”
The findings from the ongoing probe are likely to shape future maintenance protocols and may lead to design reviews if systemic issues are identified in the FCS configuration or operation.
