Air India revives grounded Boeing 777-300ER after six years of meticulous restoration
Air India has successfully revived a Boeing 777-300ER after more than six years on the ground. The aircraft, registered as VT-ALL, took off again following an extensive restoration programme led by the airline's engineering teams. This marks a key step in the carrier's push to modernise its long-haul fleet under Tata Group ownership.
The jet was grounded in February 2020 due to failing systems and outdated parts. In April 2025, Air India launched a full-scale revival effort at its Engineering Services Ltd. (AIESL) facility in Nagpur. Teams worked nearly 24/7 to overhaul the plane, replacing major assemblies like engines and landing gear while rebuilding all onboard systems.
Over 3,000 new components were fitted, and more than 4,000 maintenance tasks were completed. Every replacement and repair underwent strict testing, documentation, and oversight by India's aviation regulator (DGCA), with technical support from Boeing. The project aligns with Air India's wider strategy to expand long-haul routes and upgrade its widebody fleet amid global shortages of Dreamliner parts. The restored Boeing 777-300ER will now operate between Delhi and Frankfurt from March 31 to July 31, 2026. This replaces the smaller Boeing 787-9 on the route, boosting both passenger and cargo capacity. The revival of VT-ALL is part of Air India's broader success in reactivating all 30 previously grounded aircraft since the Tata Group took control in 2020.
The aircraft's return to service follows a meticulous, year-long restoration involving thousands of upgrades and regulatory checks. It will now serve a key European route, increasing capacity as Air India continues its fleet modernisation. This revival also reflects the airline's progress in bringing its entire grounded fleet back into operation.
