Narrative:

After engine start and initial power increase for taxi we got an engine fuel filter EICAS message. We returned to the blocks for local maintenance to repair the problem. They estimated a one hour repair. The repair required opening the aft cowl of the left engine. It appeared that the lower aft latch was not released; so when the cowl was attempted to be opened the assembly jammed. It took over an hour for the mechanics to get the bound release to unlatch before repair could be initiated. Once access was obtained; they replaced the fuel filter and bypass sensor. Overall the repair took more than two hours to accomplish. A flight crew engine run was accomplished at idle power. No problems were noted.the next flight segment had no maintenance malfunctions during ground operations. During flight; however; the same EICAS message reappeared shortly after takeoff. The message seemed to be intermittent; but being more prevalent at higher power settings. We entered holding to assess the issue and coordinate with dispatch and maintenance control. It was determined that the safest course of action would be to return. An overweight landing was accomplished with the concurrence of dispatch and maintenance. The touchdown was normal. After that return to the gate; the local mechanics wanted to release the aircraft with a diagnosis of a wiring issue causing the fuel filter message. As this was an ETOPS flight over the pacific ocean we wanted more assurance that the message was indeed a false indication and not a true predictor of a fuel related engine failure. Due to an airport curfew there was not sufficient time to further troubleshoot the problem.

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Original NASA ASRS Text

Title: B777 flight crew describes the steps taken to correct a fuel filter EICAS message that returns after takeoff and results in a return to field for an overweight landing.

Narrative: After engine start and initial power increase for taxi we got an engine fuel filter EICAS message. We returned to the blocks for local Maintenance to repair the problem. They estimated a one hour repair. The repair required opening the aft cowl of the left engine. It appeared that the lower aft latch was not released; so when the cowl was attempted to be opened the assembly jammed. It took over an hour for the mechanics to get the bound release to unlatch before repair could be initiated. Once access was obtained; they replaced the fuel filter and bypass sensor. Overall the repair took more than two hours to accomplish. A flight crew engine run was accomplished at idle power. No problems were noted.The next flight segment had no maintenance malfunctions during ground operations. During flight; however; the same EICAS message reappeared shortly after takeoff. The message seemed to be intermittent; but being more prevalent at higher power settings. We entered holding to assess the issue and coordinate with Dispatch and Maintenance Control. It was determined that the safest course of action would be to return. An overweight landing was accomplished with the concurrence of Dispatch and Maintenance. The touchdown was normal. After that return to the gate; the local mechanics wanted to release the aircraft with a diagnosis of a wiring issue causing the fuel filter message. As this was an ETOPS flight over the Pacific Ocean we wanted more assurance that the message was indeed a false indication and not a true predictor of a fuel related engine failure. Due to an airport curfew there was not sufficient time to further troubleshoot the problem.

Data retrieved from NASA's ASRS site as of July 2013 and automatically converted to unabbreviated mixed upper/lowercase text. This report is for informational purposes with no guarantee of accuracy. See NASA's ASRS site for official report.