New Delhi, 17th March 2026:
When Air India returned to the Tata Group in 2022, one of the airline’s biggest priorities was rebuilding its fleet and restoring world‑class operational capability. Among the inherited legacy fleet of 113 aircraft were 30 widebody and narrowbody aircraft that had remained long‑grounded and untouched for years. Post-privatisation, Air India committed significant resources to revive each of them.
With the return of VT‑ALL, the last of the 30 grounded aircraft, a Boeing 777‑300ER, the final chapter of this massive revival effort is now complete. In the next phase, VT-ALL and the other B777 aircraft in our fleet will undergo a full retrofit, starting 2027. With the retrofit, the aircraft will offer the new Air India experience with new seats and modern amenities while sporting our new livery.
A comeback six years in the making
VT‑ALL had been grounded since February 2020 due to multiple unserviceable systems and aging components. In April 2025, Air India initiated efforts to bring it back to full operational life to support long‑haul expansion. The aircraft entered the AIESL Nagpur MRO facility in May 2025, beginning an intensive, nose‑to‑tail restoration programme.
The scale of the task was exceptional:
3,000+ new key components installed – an undertaking rarely seen outside of deep structural overhauls
4,000+ maintenance tasks completed, including 80 mandated modifications such as the complex Longeron Modification, a crucial structural reinforcement
Replacement of major assemblies including engines, APU, inlet & fan cowls, and thrust reverser cowls
A full systems rebuild – covering air-conditioning, landing gear, hydraulics, oxygen, avionics, and engine systems – essentially reconstructing the aircraft’s functional backbone
Each part replacement, system restoration, and structural repair underwent stringent testing, documentation, and regulatory oversight by DGCA, with technical guidance from Boeing. Skilled engineering teams worked nearly round the clock to bring the aircraft back to life.
A collaborative engineering triumph
The revival of VT‑ALL was driven by seamless coordination across Air India’s base maintenance, planning, technical services, procurement and supply chain, Project Management Office (PMO) powerplant, Continuing Airworthiness Management Organisation (CAMO), and quality assurance teams. Their combined effort ensured the aircraft was restored in record time and to the highest safety and performance standards.
