UK Flagged Fuel Valve Issue On Boeing, Weeks Before Ahmedabad Plane Crash

Weeks before the Air India 787 crash, UK regulators flagged fuel valve issues on Boeing jets, prompting urgent checks. New details raise questions about missed warnings and maintenance lapses.

UK Flagged Boeing 787 Fuel Valve Risk Weeks Before Air India Crash

Source : Boeing

Editor's note: The CAA document cited in the report below is from 2015 and not a new one. In an email to ABP Live, the UK's Civil Aviation Authority stated: "Due to the update to the contact email address, our website published the document as if it was a new document."

Here is the report originally published on July 15, 2025.

Just a month before an Air India Boeing 787-8 crashed shortly after takeoff from Ahmedabad, the UK’s Civil Aviation Authority (CAA) had raised red flags about a potential safety issue involving the aircraft’s fuel control systems.

On May 15, the British aviation regulator issued a safety directive urging operators of five Boeing aircraft models—including the 787 Dreamliner—to urgently review a U.S. Federal Aviation Administration (FAA) Airworthiness Directive (AD). The directive identified concerns related to fuel shutoff valve actuators, which play a critical role in flight safety.

The FAA warning highlighted a potential "unsafe condition" across Boeing models B737, B757, B767, B777, and B787. In response, the CAA directed airlines to assess whether their fleets were affected—and, if so, to inspect, test, or replace the actuators as necessary.

Fuel shutoff valves are essential safety components that can stop fuel flow to an engine in emergency situations, such as a fire, forced landing, or major maintenance event. Any failure in this system could compromise the aircraft’s ability to operate safely.

Notably, the CAA’s notice didn't just recommend action—it mandated daily checks on affected aircraft, emphasizing the urgency of the issue.

Preliminary Report Points to Fuel Control Switches

The warning gained renewed attention following the preliminary findings of India’s Aircraft Accident Investigation Bureau (AAIB) into the Air India crash. The report revealed that both engines of the ill-fated Dreamliner lost power moments after liftoff when the fuel control switches unexpectedly moved to the "CUTOFF" position—cutting off fuel supply mid-air.

Although the FAA, in a more recent July 11 statement, said the switch design does not pose a safety risk, the UK’s earlier directive paints a more cautious picture. Boeing, in alignment with the FAA, also maintains that the system is sound, offering guidance but not issuing any new advisories in light of the crash.

Maintenance History and Overlooked Advisory

According to official records, Air India had replaced the Throttle Control Module (TCM)—which houses the fuel control switches—twice in recent years, once in 2019 and again in 2023, following Boeing’s recommended maintenance schedule.

However, the AAIB noted a crucial gap in protocol: Air India had not inspected the locking mechanism of the switches, as recommended by an FAA advisory back in 2018. The airline argued the checks were not mandatory, and thus, were not performed.

Airline CEO Urges Caution Amid Investigation

In the wake of rising speculation, Air India CEO Campbell Wilson addressed employees in an internal message, urging restraint. He emphasized that the investigation remains ongoing and stressed that the preliminary report “identified no cause nor made any recommendations.” He cautioned against rushing to assign blame.