MajorCommonFluid Leaks

Renault Scenic: K9K 1.5 dCi Injector Return Rail Banjo Bolt Washer Leak

K9K 1.5 dCi Injector Return Rail Banjo Bolt Washer Leak is a common fluid leaks fault on the Renault Scenic on the 2003–2016 cars, and we rate it major. Putting it right costs $180 to $550 at New Zealand independent workshop rates. Below is what goes wrong, the symptoms to notice on a test drive, where to look, and what to ask the seller before you hand over any money. It is one of 6 documented faults on the Renault Scenic.

Vehicle: Renault Scenic
Engine: 1.5L
Years: 2003–2016
Fuel: diesel
System: Fluid Leaks

This page covers the Renault Scenic as a model. Some faults only affect particular engines or build years — enter a plate below to narrow the list to one car.

All Renault Scenic faults6 documented faults on this model

What you are looking at

What goes wrong

The K9K 1.5 dCi common-rail diesel unit fitted to Scenic II and Scenic III uses the same injector fuel return rail banjo bolt sealing arrangement as other K9K applications. Copper or aluminium crush washers at the banjo fittings harden and lose elasticity through heat cycling, eventually cracking and allowing diesel fuel to leak from the low-pressure return circuit. Scenic family MPV driving patterns involving frequent short cold trips followed by sustained motorway runs create extreme thermal cycling stress on these washers and increase leak frequency relative to other K9K applications with more consistent driving profiles.

What you would notice

Diesel fuel odour from engine compartment during and after driving
Wet or oily residue around injector return rail banjo bolt fittings
Smoke or steam visible from engine bay particularly after hot motorway driving
Unexplained increase in fuel consumption
Carbon staining on exhaust manifold adjacent to injector return area

How to check it

Where to look. Top of K9K engine cylinder head at injector return rail banjo bolt fittings, near the inlet manifold and turbocharger housing

With engine at operating temperature, inspect banjo bolt fittings on the injector fuel return rail for wet diesel seepage, discolouration or residue at the washer interface; examine exhaust manifold surface below the banjo fittings for black carbonised fuel deposits indicating historical or active leakage; review service history for evidence of banjo washer renewal or fuel system attention.

Parts involved: Fuel injector.

What it costs to put right

$180 to $550 at New Zealand independent workshop rates. That is for this job on its own, not for the car.

An estimate, in NZD, for the repair as normally carried out. What a specific car costs depends on which part has failed and what it damaged on the way — treat this as the floor for a negotiation, not a quote.

Ask the seller

“Have the injector return banjo bolt crush washers been replaced?”
“Has any diesel smell been noticed from the engine bay?”
“Has any fuel leak work been carried out on this vehicle?”
“Is there any smoke or smell after extended motorway driving?”

Now check the Renault Scenic you are actually looking at

Everything above is true of the model, and it is free. What it does not tell you is whether THIS car has been looked after: its odometer history and whether the reading has ever gone backwards, whether there is still money owing on it, whether it has been reported stolen, how many owners it has had and what it is really worth today. That comes from the official records for that plate. Enter the plate for the free details, or get the full history and a market valuation from $13.49.

Not sure what you would be paying for? See what a full KickTyres check includes.

Where this comes from

The failure described above is documented in published sources — owner forums, technical service bulletins, recall notices and workshop write-ups — held in our fault database. The inspection instructions and the cost estimate are KickTyres’ own interpretation of them, and it is a starting point for an inspection rather than a manufacturer statement.

Renault Scenic buyer questions

Is k9k 1.5 dci injector return rail banjo bolt washer leak serious on a Renault Scenic?

We rate it major and common on the Renault Scenic. The K9K 1.5 dCi common-rail diesel unit fitted to Scenic II and Scenic III uses the same injector fuel return rail banjo bolt sealing arrangement as other K9K applications. Copper or aluminium crush washers at the banjo fittings harden and lose elasticity through heat cycling, eventually cracking and allowing diesel fuel to leak from the low-pressure return circuit. Scenic family MPV driving patterns involving frequent short cold trips followed by sustained motorway runs create extreme thermal cycling stress on these washers and increase leak frequency relative to other K9K applications with more consistent driving profiles.

How much does it cost to fix on a Renault Scenic?

$180 to $550 at New Zealand independent workshop rates. That figure is for this job on its own. A car showing the symptoms on this page is usually worth either walking away from or negotiating down by at least the repair figure.

Which Renault Scenic years are affected?

Our research records this fault on the 2003–2016 Renault Scenic. Build dates move around, especially on imported cars, so treat the range as the years to look hardest at rather than a guarantee either way. The official records tell you the exact build and first registration date for the car in front of you.