Air India Returns Boeing 777-300ER VT-ALL, Revitalising Grounded Fleet.

An important turning point in Air India‘s post-privatization restructuring under the Tata Group has been reached with the completion of the restoration of its legacy grounded fleet. Rebuilding its fleet and regaining operating competence were among the airline’s top concerns when it rejoined the Tata Group in 2022. Thirty widebody and narrowbody aircraft that had been grounded for a number of years were among the 113 aircraft that Air India had inherited at the time.

The airline has completed this stage of its fleet restoration program with the return to service of VT-ALL, a Boeing 777-300ER and the final of the 30 grounded aircraft. Beginning in 2027, the aircraft and other Boeing 777s in the fleet will receive a complete makeover that will include new seats, renovated cabins, contemporary amenities, and a redesigned livery for the airline.

Due to several technical problems and aged components, VT-ALL had been grounded since February 2020. In order to fulfil its long-haul development goals, Air India started restoring the aircraft to operational condition in April 2025. In May 2025, the aircraft arrived at the AIESL MRO facility in Nagpur, where it began a comprehensive restoration program.

Over 3,000 components had to be installed, and over 4,000 maintenance activities, including about 80 required modifications like structural reinforcements, had to be finished. The auxiliary power unit (APU), engines, and important exterior parts were among the major assemblies that were replaced. Critical systems were also restored and tested, including avionics, landing gear, hydraulics, and air conditioning.

According to the airline, Boeing provided technical support while the Directorate General of Civil Aviation (DGCA) oversaw the repair. The project involved the cooperation of several Air India divisions, including maintenance, engineering, planning, and quality assurance.

The Airworthiness Review Certificate (ARC), which attests to the aircraft’s compliance with safety regulations for commercial operations, was awarded after it successfully finished its test flight.