Japan Airlines was forced to replace a Boeing Dreamliner on Sunday after engineers found a faulty air pressure sensor on the jet's modified battery container.
The incident, which did not pose a serious safety risk, occured just one day after the carrier resumed its full B787 service.
JAL decided to replace the B787 with a Boeing 767 for the Tokyo to Bejing flight.
The airline said the problem was caused by two small holes on the battery container, which are needed to provide ventilation, being mistakely sealed by Boeing engineers.
Last month, All Nippon Airways reported a "minor" problem with a modified Dreamliner undergoing test flights (see online news, May 16).
The carrier said a damaged electrical distribution panel, unrelated to the battery system that grounded the entire Boeing 787 fleet in January, was to blame.
ANA said a nut connecting an electrical wire to a power distribution panel had not been tightened properly by a Boeing maintenance worker. The panel was left blackened after the nut vibrated and overheated due to friction during a test flight.
The pilot was alerted to the problem when an error light flashed in the cockpit.
On Friday, Thomson Airways became the first UK airline to take delivery of a Boeing 787 Dreamliner (see online news, May 31).
For more information, visit jal.com.
Report by Graham Smith
