Hi All,

I wonder if anyone else has some advice on this problem.
Am replacing the glow plugs on my A6 C6 2.7TDI BSG motor.
The original defective ones are metal ( red disc ) Beru 266 014 - now this "model" has been superseded a number of times by Beru and the latest recommended Beru part is GE133 and this is confirmed by multiple online parts finders.
On the old glow plugs is also stamped the OEM VW-AG 059 963 319E which again coincides with the OEM number if you search various part finders... there are of course many equivalent glow plugs from NKG, Bosch, etc etc all cross referenced by car model and motor code BSG and the  OEM VW-AG 059 963 319E part number..

BUT!!!!

The originals I have removed are 127mm over all length and the fitting length ( the pin ) is 24.6mm as measured by yours truly.
ALL the recommended replacement glow plugs from the various manufacturers are overall 130mm in length and the fitting length is 28mm  - so just over 3mm longer.
All other specs are identical to the originals...

Has anyone experience in fitting the newer spec ( longer ) glow plugs in the 2.7TDI?
there is a long list of equivalents for the OEM VW-AG 059 963 319E part number and it is quite widely used in VAG motors.
e.g.

Beru GE133
Beru GE115
Bosch 0 250 403 009
Ridex 243G0006P
Febi 176203
NKG 8888
And many more -- all 130mm in length and the pin 28mm.

I have searched widely for any further info on this but apart from one post in another Audi forum from 2019 with the same problem but no clear answer I haven't come up with much ... would hate the piston to contact the longer pin... :0

Thanks
John

Edited August 14, 2025Aug 14 by GJC
spelling

1 hour ago, GJC said:

Hi All,

I wonder if anyone else has some advice on this problem.
Am replacing the glow plugs on my A6 C6 2.7TDI BSG motor.
The original defective ones are metal ( red disc ) Beru 266 014 - now this "model" has been superseded a number of times by Beru and the latest recommended Beru part is GE133 and this is confirmed by multiple online parts finders.
On the old glow plugs is also stamped the OEM VW-AG 059 963 319E which again coincides with the OEM number if you search various part finders... there are of course many equivalent glow plugs from NKG, Bosch, etc etc all cross referenced by car model and motor code BSG and the  OEM VW-AG 059 963 319E part number..

BUT!!!!

The originals I have removed are 127mm over all length and the fitting length ( the pin ) is 24.6mm as measured by yours truly.
ALL the recommended replacement glow plugs from the various manufacturers are overall 130mm in length and the fitting length is 28mm  - so just over 3mm longer.
All other specs are identical to the originals...

Has anyone experience in fitting the newer spec ( longer ) glow plugs in the 2.7TDI?
there is a long list of equivalents for the OEM VW-AG 059 963 319E part number and it is quite widely used in VAG motors.
e.g.

Beru GE133
Beru GE115
Bosch 0 250 403 009
Ridex 243G0006P
Febi 176203
NKG 8888
And many more -- all 130mm in length and the pin 28mm.

I have searched widely for any further info on this but apart from one post in another Audi forum from 2019 with the same problem but no clear answer I haven't come up with much ... would hate the piston to contact the longer pin... :0

Thanks
John

Hi I think you will find there is little chance of contact as the end of the plugs sit at the top of the cylinder head swirl bowl, could be the originals were not that efficient so someone changed the dimensions to improve the operation, apart from which if the piston contacted the end of the plug you would have already lost a big end bearing cap.

Steve.

John.

I have no knowledge of this but I can suggest a way to find out if the longer plugs will cause a problem. Stick a blob of Plasticine or BluTack or something similarly soft on the tip of a short plug so that it extends it by another 5 mm. Screw the plug in and turn the engine over by hand. Unscrew the plug and look for the flattening of the blob of soft stuff.

1 hour ago, Stevey Y said:

Hi I think you will find there is little chance of contact as the end of the plugs sit at the top of the cylinder head swirl bowl, could be the originals were not that efficient so someone changed the dimensions to improve the operation, apart from which if the piston contacted the end of the plug you would have already lost a big end bearing cap.

Steve.

Cheers Steve for the advice ... I am starting to think that it must be OK because I can't find any word about demolished motors after recommended glow plugs etc...

Would love confirmation though from someone that has changed them to the currently available 130mm lengths...

Do you know of any link to images of what the cylinder head combustion chamber looks like on a VAG TDI? I assume they would be fairly similar for the 4 valve designs... 
Thanks again.

1 hour ago, cliffcoggin said:

John.

I have no knowledge of this but I can suggest a way to find out if the longer plugs will cause a problem. Stick a blob of Plasticine or BluTack or something similarly soft on the tip of a short plug so that it extends it by another 5 mm. Screw the plug in and turn the engine over by hand. Unscrew the plug and look for the flattening of the blob of soft stuff.

Hi Cliff,

Will have a play with your idea tomorrow and see if I can come to a conclusion.
Thanks for taking the time!

I don’t see the length of the new glow plugs interfering with the engine. If you’ve not removed them, then be careful. Spray PlusGas on them 2-3 days before removing. Also do it with engine hot. Use a 1/4” ratchet so you feel the torque when removing. If one breaks you’re in a world of pain.

OK, sorry for the long delay in replying but life got in the way as usual...
So all 6 changed and I can confirm no pistons hit any glow plugs... 🙂

Was actually very straight forward, soaked them over night in Ludwig Rust Remover and carefully removed them with a setting of 20 Newton/M on the torque wrench ( all loosened with less - surprised as the motor has 333,333km on it and these have never been changed since I have had it from 90,000km ) after blowing out and vacuuming all the crap out ( mainly crumbling rubber sockets ).

I could reach all 6 without a flexible connection after removing the swirl flap motors ( 3 set screws to each ). What was very useful was a short length of plastic hose that snuggly fitted the end connector ( 4mm inner diameter ) to remove and place the new ones - it had enough grip to start the new ones in their threads.

Faults cleared with OBDeleven and all good to go.

So to conclude - the extra 4mm didn't create a problem - the fitted length was 130mm ( pin 28mm ) and any of these on AutoDoc would have done.
Thanks for all the advise etc.