Air India Brings Last Grounded Aircraft VT-ALL Back into Service

Fleet Restoration Programme Reaches Completion

After rejoining the Tata Group in 2022, Air India launched a systematic effort to rebuild its fleet and restore operational capacity. At that time, the airline inherited 113 aircraft, including 30 that had been grounded for several years. The airline allocated resources to return these aircraft to service.

With the return of VT-ALL, a Boeing 777-300ER, Air India has completed the restoration of all 30 previously grounded aircraft. The aircraft is now prepared for operations, marking the end of this phase in the fleet revival programme.

VT-ALL had been grounded since February 2020 due to multiple technical issues and ageing components. In April 2025, Air India initiated work to restore the aircraft, which entered the AIESL MRO facility in Nagpur in May 2025 for detailed maintenance and overhaul.

The restoration involved installing over 3,000 components and completing more than 4,000 maintenance tasks, including required structural modifications. Major assemblies, such as engines, auxiliary power unit (APU), and external structures, were replaced, along with a full rebuild of key systems, including hydraulics, avionics, air-conditioning, and landing gear.

All work was carried out under regulatory oversight from the Directorate General of Civil Aviation (DGCA), with technical support from Boeing. The aircraft also underwent required testing and documentation before being cleared for operations.

VT-ALL has successfully completed its test flight and received the Airworthiness Review Certificate (ARC), allowing it to re-enter regular service.

The project involved coordination across multiple teams within Air India, including engineering, maintenance, planning, supply chain, and quality assurance.

With all previously grounded aircraft now operational, Air India moves into the next phase of its fleet plans. The airline has stated that its Boeing 777 aircraft, including VT-ALL, will undergo cabin retrofit from 2027, introducing updated interiors and a refreshed livery.

The completion of this programme reflects the airline’s focus on restoring fleet availability and strengthening its operational readiness.